S MANOA WITH INBOARD FREEWHEEL aliVICL SM -124 10,000 AND11,500 HYDRAULIC TORQUE CONVERTER THREE-STAGE AVVAIIIN| Pe E>SM-124 SERVICE MANL MODEL CO 10,000 AND 11,500 HYDRAULIC TORQUE CONVERTER STANDARD THREE-STAGE WITH INBOARD FREEWHEEL ORIGINAL ISSUE—JANUARY 1966 REVISED ISSUE—JUNE 1970 REVISED ISSUE—NOVEMBER 1976 REVISED ISSUE—APRIL 1977 REVISED ISSUE—NOVEMBER 1977 REVISED ISSUE—AUGUST 1980 Twin Disc, Incorporated 1328 Racine Street Racine, Wisconsin, U.S.A. SERVICE INFORMATION Each series of Maintenance Manuals issued by Twin Disc, Incorporated is reviewed accuracy at regular intervals. When required, changes are made in the manual to provide the la information regarding current design and maintenance practices of the product, In addition, individual product Service Bulletins are issued to provide the field with immed notice of new service information. ‘These Service Bulletins are distributed to all the Twin Disc Distributorships throughout United States and in many foreign countries. To be sure you have the latest Service Information on your Twin Disc product, contact Twin Disc Distributor for Service Bulletins. or write to the Service Engineering Department, T Disc, Incorporated, Racine, Wisconsin, U.S.A.REVISION AND REISSUE DATA REVISION AUGUST 1980. Added new title and revision data pages and revised torque charts. Revised address on the hydraulic tester information A NOTE: "Flagging" indicates area revised.models LU- U,UUU and II, Section 1. Section IL Section II. Section IV. Section V. Section VI. Section VII. Section VIII. Section IX. Section xX. Section XI. Section X11. Section XIII Section XIV. Table of Contents Page INTRODUCTION... .. wena eee eee = 4 DESCRIPTION ...... tenes . 6 PRINCIPLES OF OPERATION ... . sees ence eeeee 12 LUBRICATION AND FLUID SYSTEM... 06-0... 20. 005 13 PREVENTIVE MAINTENANCE. .... 0-20-20 0e 000s eee eens 16 ‘TROUBLE SHOOTING 18 REMOVAL .......... . 23 POREASSEDMBES G5 fceg cscs sae uti gin cheng «ght fi 23 CLEANING AND INSPECTION ......... 00. 0.0.00005 . 8B ASSEMBLY = 4. (sr oy. GREECE Fe oo x neon 29 INSTALLATION ........ BT cenoe nna meni Kivi atm RECOMMENDED FLUIDS, OILS AND GREASES .........- oe 4 SPECIAL TOOLS ...... . fee veweaeeee +. 46 Eee aaapecenepsnarcne-onee veteeee ene eee 46 “IMPORTANT NOTICE. Because of the possible danger to person(s) or property from accident which may result from the use of manufactured products, it is important that correct procedure be followed: Products must be used in accordance with the engineering information specified i the catalog. Proper installation, maintenance, operation procedures must be observed. Inspectio should be made as necessary to assure safe operations under prevailing conditions. Proper guard and other suitable safety devices or procedures as may be desirable or as may be specified in safet codes should be provided, and are neither provided by Twin Disc, Incorporated nor are th responsibility of Twin Disc, Incorporated.”SIHHHCH COVER PLATE ASSEMB. OFERAIIG Sit SING cuurch PRESSURE F OUTPUT HOUSING Pipe FLANGE inpur'sy HAND-HOTE PLATE NEN clutch Driv PLATE ASSEMI Figure 1. Model CO-10,000 & 11,300 Series Three-Stuge ‘Vasque Converter (2/4 Front View)Models CO- 10,000 and 1 GREASE FITTING NAME AND. INSTRUCTION PLATE cuutcH HOUSING FiuTER LIFTING EYE BOLT ea FILTER BRACKET ASSEMBLY ‘OUTPUT HOUSING. REAR FLUID SEAL DRAIN LINE RESERVE TANK ASSEMBLY Figure 2. Model CO-10,000 & 11,500 Series Three-Stage Torque Converter (3/4 Rear VieHydraulic lorque Converter Section 1. INTRODUCTION 1. GENERAL. A. Scope. This maintenance manual con- tains instructions and illustrations for the opera- tion, removal, disassembly, assembly, and installa- tion of Twin Disc, Incorporated Hydraulic Torque Converter Mode! CO-10.000 and CO-11.500 Series. Engineering details and performance characteristics of the three-stage hydraulic torque converters may be obtained by writing to Twin Disc. Incorporated, Rockford Works. Rockford. Illinois. U.S.A B. Special Tools. The manual also con- tains engineering drawings for the fabrication of special tools that may be used during disassembly and assembly procedures. Twin Disc, Incorporated will not manufacture these tools for general use C. Parts List. A complete parts breakdown, with exploded view illustrations, is provided to facilitate the ordering of spare or replacement parts. D. Trouble Shooting. ‘The manual also con- tains a trouble shooting table which will assist in determining the cause of functional difficulties that may occur, Proper use of the symptom, cause, and remedy columns of the table will determine whether a simple repair can be accomplished on the torque converter or complete disassembly is necessary. 2. DISTRIBUTION. This maintenance manual should be made available to, and read in its entirety by, all personne! responsible for the operation or maintenance of the hydraulic torque converter. A thorough understand- ing and application of the material in this manual will result in lengthy and satisfactory service from the converter. 3. ORDERING PARTS. A. Source. Renewal Parts, repairs, and “Parts Operation Service Kits” may be obtained from your Authorized Twin Disc Distributor or Service Dealer. You can find him listed under POWER TRANSMISSION EQUIPMENT in the Yellow Pages of most metropolitan telephone directories. B. Method. It is highly imperative tt Model, Specification, and Serial Numbers unit be included when ordering a service part. numbers will always be found stamped on th verter instruction plate. Always give the number of the illustration containing the pa item number of the part, the description of th. and the quantity required. Do not use the “complete”, but state exactly each item w Do not designate the quantity by “sets”, but s the number of parts required NOTE If detail part numbers of the hydraulic torque converter are desired, write to ar address given in Paragraph 3A, and sub- mit the specification number. 4, PARTS SHIPMENT. A. ‘iethod. Specifically state wheth, parts are to he shipped by freight, express wheiever ordering spare or replacement pa ‘ng instructions are not specified on the we wis! use our own judgment and take int n tine as well as expense. Twin INRA aNY Nivua was way" YT INV NIT ANBA, 4 nee A ‘aunts + a + aAIWA INaA- avo amgHydraulic 18. MASTER CLUTCH SLIDING SLEEVE THROW- OUT BEARING. The masterclutch throw-out bearing is grease lubri- cated with a hand grease gun through a fitting and hose connection attached to the right side of the clutch housing. Use an approved grease as listed in Table IV, paragraph 50. Lubricate every 10 hours of operation or daily. 19. FLUID PRESSURE. ‘The auxiliary fluid pumpand its built-in relief valve control the converter charging fluid pressure. The pressure gauge, indicating the charging pressure, is is connected in a “tee” connection at the fluid filter outlet. If conditions are normal, and the air is properly vented from the converter circuit, the oil pressure will indicate full pressure (rated) immedi- ately upon starting the engine and engaging the master clutch. The pressure will drop to zero, when stopping the engine or disengaging the master clutch 20. FLUID TEMPERATURE. ‘The temperature is taken at the turbine housing. ‘The gauge is mounted next to the pressure gauge in the fluid filter and gauge mounting bracket. Normal temperature for operation is 180 degrees — 220 de- gtees F. Maximum temperature is 250 degrees F. 21. FLUID COOLING. It is recommended that the fluid be cooled with a hheat exchanger rather than a radiator, if the instal- lation lends itself readily to an exchanger instal- lation. Heat exchangers hold the fluid to a more desirable minimum than radiators and thereby cause less variance in fluid viscosity. Section V. PREVENTIVE MAINTENANCE 22. GENERAL. A. Lubrication. The unit lubrication was covered previously. A daily check should be made of the fluid and oil levels in the end plate sump, the output housing sump, and the reserve tank. B. Qverhaul Interval. Acomplete overhaul of the Model CO-10,000 and CO-11,500 series torque Converter should be made at the same time that the engine is overhauled. All parts showing signs of wear, fatigue, etc., should be replaced at this time. lorque Converter 23. OIL AND FLUID SYSTEMS. A. Oil Level. Check the oil level end plate sump and the output housing sump Check oil level when unit is static. Mainte level between the “low” and “full” marks gauge. Add oil as soon as the level drops be very near to the “low” mark, Use an appro. (paragraph 51, Table V) SAE 30 or 40 or the type of oil used in the engine crankcase. ( pacity is 1 qt. U.S. measure in the end plate and 4-1/2 qts. in the output sump. The oil is into the sumps through their oil level gay, breather assembly mounting nipples. B. Fluid Level. The converter circ the torque converter must contain a solid fluid to operate efficiently. Check the fluié in the reserve tank daily, with the fluid at op: temperature. Shutting down immediately after « ing the unit the level should be maintained “fall” mark. The fluid is poured in the tank t the fluid level-gauge-and-breather assembly ing nipple. The capacity of the converter circuit is 7 U.S. gals. less cooler and conn lines. C. Oil Change Interval. The lubricat in the end plate sump and spiral gear bearii output housing sump is changed every 1000 operation or every 3 months of operation, whi occurs first. (1) Draining. ‘The end plate st rained by removing the 1/2-inch pipe cap fr bottom of the clutch housing which connect the sump. ‘The output housing sump is drained by ing the 1/2-inch square-head pipe drain plug bottom of the housing. (2) Filling. The end plate sun the output housing sump are filled through th level gauge and breather assembly mounting ni ‘The end plate sump capacity is 1 U.S. quar output housing sump capacity is 4-1/2 U.S. « D. Converter Fluid Change Interval. converter fluid is changed every 1000 hrs. o ation or 3 months elapsed time, whichever : first. (1) Draining. The converter is d by removal of the socket head 1/2-inch pipe 1models CU-1U,UUU and I 13. CONVERTER CIRCUIT FLUID FLOW A. General. The converter internal fluid flow between the members of the converter, (impel- ler, turbine, and stators), was cove ed in paragraph 12. This paragraph will be devoted to the fluid circuit into and out of the converter B. Fluid Flow. The charging pump traws fluid from the reserve tank through the inlet strainer and displaces it through the fluid filter and into the end plate. A passage in the end plate routes the fluid through the seal carrier and into the cavity behind the impeller wheel A labyrinth seal formed by lands and grooves on the impeiler wheel and end plate confines the fluid, causing it to flow into the toroidal chamber through holes drilled in the front side (toward engine) of the impeller wheel The action of the impeller wheel imparts momentum and force to the fluid through the converter internal circuit increasing the pressure across the circuit. The converter outlet connection to the fiuid heat exchanger is at the outer diameter of the converter internal circuit, where the pressure is high. The fluid circulates through the heat exchanger and returns to the rear of the impeller wheel at the charging area (low pressure) to begin another cycle. ‘The pressure drop of differential between impeiler inlet to housing outlet is the cooling circulating pressure; the converter acts as its own cooling pump. The orifice bleed connected to the highest point in the cooling circuit vents the air from the circuit into the reserve tank and supplies a return for oil constantly displaced into the circuit from the charging pump. 14. FREEWHEEL OPERATION. The freewheel is a one way, or overrunning clutch. It is engaged and disengaged automatically. The cam, since it is connected to the impeller wheel, is turning at engine speed when the master clutch is engaged. The outer race is a part of the turbine wheel and is therefore turning at converter output shaft speed. When the engine (and cam) is turning faster than the converter output shaft the freewheel is disengaged. Under these conditions the freewheel rollers are at the low area on the cam and therefore do not apply pressure to the outer race. However, if the load should try to drive the output shaft faster than the input shaft the rollers move up the ramps of the cam and cause the freewheel to engage. Under this condition the rollers are connected solidly between the cam and outer race. It can be seen that under normal conditions (engine speed greater than output shaft speed) the frees ‘tot affect converter operation. When th tempts to back-drive through the converte connection exists between the engine an therefore, engine braking is available < verter output shaft Since the bladed com the converter ate being driven by the absorb some of its energy and add to braking. CAUTION When the freewheel is engaged, engine speed should be watched. § there is a direct mechanical conne, between engine and load, the en governor will not limit engine speed Section IV, LUBRICATION AND FLUID SYSTEM 15. GENERAL. The lubrication system in this series i from the converter fluid system. Two liquids are used; a converter fluid, see in paragraph 49, for the converter circuit cation of the seals and freewheel! unit; enj case oil (SAE 30-40 or as in engine) se an paragraph 51, for the flu'd pump drive parts drive, front ball bearing, rear doub bearing, and output shaft spherical roll lubrication. 16. END PLATE SUHP. ‘The end plate sump contains lubrication converter impeller ball bearing and fluid p The pump drive chain runs in the lubri carrying it around to wet the sprockets an ball bearing (converter impeller hub), these parts. A bayonet-type oil level breather assembly is mounted with a nip the clutch housing and into the end p. ‘The end plate sump holds 1 qt. of oil. 17. OUTPUT BEARING AND SPIRAL GE ING SUMP. This sump is filled with oil to a poir low the output shaft, so the rear turt double-row ball bearing and the output sh cal roller bearings are running submerge:Hydraulic lorque Converter their lower sections. The bearings pick up oil, NOTE carrying it around for their lubrication and the lubri- cation of the governor drive parts; spiral gecz, shaft gear, and the shaft bearings: The three oil level gauges used on the con verter assembly are very similar in con struction. However, the bayonets are differen lengths and marked different distances fro: ‘The oil sump level gauge is a bayonet-type gauge Het onde ta apenas and breather assembly and is mounted with a nipple in the output housing sump. The oil level is checked Therefore it is very important for accurate cold, or at room temperature. The sump at the “full” fluid levels that the gauges are used in their mark contains 4-1/2 qs. of oil. location. See figures 5, 6, 7 |. 2.62» } {203002-8 nu Fo] cow 10.62 —__________ Figure 5. Oil Level Gauge for Converter Reserve Tank, Wa} bya )&tos08a-a LUBE On rut] [tow L —_-—$_$_—+—_—_ 47s Figure 6. Oil Level Gauge for End Plate Sump ka Low 10,62——___________| Figure 7. Oil Level Gauge for Standard C-3 OutputModels CO-10,000 and | ‘he bottom of the turbine housing. To aid 1n draining open the vent valve on the top of he housing. Allow sufficient time to drain. Remove the square-head 1/2-inch pipe plug from the reserve tank. Drain the heat exchanger of radiator by removal of the lower fluid connection. (2) Filling. Tighten all connections and install drain plugs in the bottom of the turbine housing and reserve tank. Fill the unit through the highest located opening, if one exists on the radiator ot heat exchanger. Open vent valve on the top of turbine housing, while fill ng, to exhaust air. When fluid flows from vent valve, close the valve. Fill the reserve tank towithin aa inch o- the “full” mark, Secure filler caps on heat exchnger and reserve tank. Start the engine and run at half throttle. Check all fattings for leaks and check the pressure gauge for steady reading of operational pressure 20-p.s.i.). Shut down engine and check the fluid level in the reserve tank frequently. Fill to “full” mark. The system holds 7 U.S. gallons less the volume of heat exchanger and connecting lines. Use a fluid as listed in the approved fluids table para- graph 49. If the converter is stopped before filling and venting is completed, the entrapped air inside the unit will expand and force fluid back into the reserve tank. This may cause the reserve tank to overflow To remedy this, keep the converter oper- ating until all the air in the system is removed by the “bleed-off”, provided through the return line to the orifice filter into the reserve tank 24. FLUID SYSTEM COMPONENT PARTS. A. Fluid Filter. (). Fluid Pitter Change Interval. The fluid filter element should be changed at each fluid ‘change interval (1000 hrs. of operation or 3 months elapsed time). Under certain extreme dust conditions more frequent filter element changes may be required. A service filter kit is available consisting of an element (25 micron) and a case gasket (2). Removal Remove the filter drain plug 13/16 hex-head (5/8-18 thread and drain the filter. Disconnect the pressure gauge line and pres- sure line from the “tee” fitting at the bottom of the filter. Disconnect the pump pressure line from the filter inlet fitting, Remove the four hex-head cep screws, nuts, and lock washers retaining the filter to the bracket. Remove the filter assembl th s procedure for installation, To change just the filter eler quired at fluid change interval, the 1-inc nut and cover assembly is removed, aft moving the drain plug and draining the { The case cover gasket is removed andr part of the element replacement operatio: element removed wipe the dirty flui¢ out ¢ case with clean cloths. Install a new filte caseover gasket, and install the cov cover Install the filter drain plug. Fil system (Paragraph 22D). Check for le starting the unit. Check and fill fluid ret B. Inlet Filter. To change ot cl let filter the fluid system should be dre paragraph 22D). Remove the ten hex-hea lock washers securing the reserve tank ¢ to the top of the tank. Remove the cover gasket. Reach into the tank near the | with a pipe wrench remove the inlet fill The inlet filter screen should be cleane 1000 hrs. of operation or 3 months, whiche first, With the inlet filter screen removed nections to the reserve tank disconnec out the reserve tank with a suitable solv install the clean inlet filter screen. Reverse the above removal proc: installation and fill the fluid system (see 22D). C. Heat Exchanger. The heat ex supplied by the original equipment mai Cooling fluid with a heat exchanger, rat radiator, is strongly recommended; fluic tures then will be held to a more desirable A heat exchanger is recommended becaus normally used in the converter circuit to considerable viscosity change with te This change in viscosity also will vary efficiency unless the fluid temperatun uniform within the range of 180 degre degrees F. The minimum recommended flu ature is 160 degrees F. To remove the changer; first drain the fluid system (paray and then disconnect the fluid inlet and o! from the exchanger. Dismount the exche its mounting brackets and remove it. Cle: changer with a suitable solvent and ret Pressure flushing equipment. Re-instal changer in reverse to above procedure ar vent the fluid system (paragraph 22D).D. Orifice Filter. Remove the element from the orifice filter after every 200 hours of operation or 2 weeks elapsed time, whichever occurs first The element is screwed into the filter head and is removed with a 13/16-inch socket or wrench. After removing the filter head and element assembly, re- move the element assembly from the filter head and loosen the disc retaining nut, so cleaning of the discs will be easier. Slosh the element assembly in asuit- able cleaning solvent and blow dry with compressed air. Re-install the orifice filter assembly in reverse to above removal procedure, using a new copper-as- bestos gasket. E. Reserve Tank. The reserve tank is re- moved for cleaning or replacement as follows: Drain the fluid system (see paragraph 22D). Disconnect the pump inlet suction line from the reserve tank pipe nipple. Disconnect the front seal drain line and the rear seal drain lines from the reserve tank pipe nipples. Remove the two hex-head cap screws retaining the upper tank bracket and filter bracket to the converter housing. Remove the two lower tank bracket hex-head cap screws, securing the tank to the lower section of the converter housing. Remove the reserve tank assembly. Reverse the above procedure to re-install the reserve tank and fill the fluid system (see paragraph 22D). F. Fluid Pump. The fluid pump is removed for inspection, cleaning or replacement as follows Drain the fluid system (paragraph 22D). Remove the six round slotted head machine screws, which retain the hand hole plate to the clutch housing. Remove the hand hold plate and gasket from the clutch housing. Reach in through the hand hole and remove inlet and outlet lines and the four hex-head cap screws and lock washers, securing the fluid pump to the sprocket housing and end plate assembly. Remove the fluid pump and gasket. It is recommend- ed that the fluid pump be sent back to the factory, when internal pump repairs are required. Reverse the above procedure to re-install the fluid pump. Refill the fluid system (see paragraph 22D.) 25. PERIODIC VISUAL INSPECTION. A. General. Frequently inspect the mount- ing parts of the hydraulic torque converter and clutch assembly. Replace any damaged parts. B. Heat Exchanger Connecting Lines. In- Spect the lines for leaks, kinks, or other damage. Hydraulic lorque Converter C. Pressure and Temperature Gauge A blies. Periodically inspect the pressure and tt ature gauge assemblies for damage. Repl damaged gauge. If a gauge is suspected of inaccurate, replace the gauge with one of | accuracy to determine the extent of malfunctic D. Oil Seals. Periodically inspect the and rear areas of the end plate and output he assemblies, for evidence of oil seal leakage place a leaking seal E. Oil Filter. Periodically inspect t filter mounting and connecting lines for con and security. Replace damaged parts and c Teakage conditions F. Reserve Tank. Periodically inspe reserve tank mounting brackets and connecting for damage and leaks. Replace damaged pari correct leakage. Inspect the fluid level gaug spect the reserve tank cover plate and gash damage, security, and/or leakage. Replace da parts and correct leakage. G. Over-center Master Clutch. Period inspect the clutch linkage and visible parts clutch through the upper cover plate openit damage and defects. Replace damaged parts Section VI. TROUBLE SHOOTING 26. GENERAL. This section of the maintenance manual has Prepared to assist maintenance personnel in tr shooting the hydraulic torque converter and center clutch assembly. When trouble shootin ways remember to consider the entire power 27. TROUBLE SHOOTING CHART. The trouble shooting chart (Table 1) is organiz three columns. Proper use of the chart will < the rapid determination and repair of any funct difficulties that may occurmoaqdeis LU-1U,UUU anda I Table I. Trouble Shooting. Symptom Cause Keo 1. Loss of fluid from converter. 14. 13. 1-4. 1-5, 17. Leaking Seals. Leaking fluid lines and/or connections. Leaking converter. Leakage around out- put shaft or into tube oil chambe Losing fluid into lube oil chamber. (End plate), Excessiveleakage past seals. Overflowing reserve tank. 1-4. 12, 1-3. 15. 1-6. Overhaul an:t ant replac: Replace defec've Ln connections. Cth i with uni: in cperat’ a, sure present Check ord t ghten nuts securiig go ke while syste:ris 9, > ati pressure Disossenble t12 (10 ve inspect for 2 misiy at gasket. Keplace sus seal gaskets as req’ = ‘This indicates werr seal, allowing {Ibi« 1 to the lube cil chat’ the {aid pump shaf ‘This may be indicat Pressure gave rest i: low pressure nay ao that fltié filter + caused by converter 11 ing lube oil zkanber o: entering turbine bea:in ber. To check this, 4is seal drain lines then ply; so fluid from the rece. will not escape. Wit? operating observ ical seal drain out’et, nif ive (a steady stream) place ground joint serls A defective fluid jam permit the fluid tc stra from the converter to serve tank, when :‘e inoperative. This wo caused by gravis, » 2 converter is Paste « tank. Replace pig |-7 ped-up fluid pomp irk or line could resn:+ intmyarauiic torque TConverter Table |. Trouble Shooting. Symptom Cause Remedy 2. Poor performance and overheating of con- verter. 2-1. Air in system. 2-2. Low basic pressure. 2-3. Inadequate cooling, 2-4, Fluid level too low. ea. verter pumping fluid into reserve tank while the 1 pump couldn't displace | into the converter. Low oil ¢ sure would be a tip-off to possibility of this condit Clear line. 1-7 A stopper pressure line to the conv from the bottom of the f “Tee” connection could ci the same result as above. C line. Pressure would be no and not be an aid to fin trouble. Open aconnection at the hig point in the system (Lor Fitting) with the unit operat Ifany air is present, the sy: must be thoroughly checked cause temoved. Check | level in reserve tank, Be the orifice filter is clear the small bleed hole open. and vent system as covere paragraph 22D . If pressure reading is normal, check fluid lines leaks and restrictions. Cl for clogged fluid filter. Cl fluid pump relief valve. (S open). Check seal drains excessive leakage. Check accuracy of the gauge. Where a radiator is used ct the finned area for bugs, lea’ etc. Clean thoroughly. Ct radiator or heat exchanger restrictions in flow. Cleat replace. Check radiator belts for slippage and condi Replace defective belts. fective engine thermostat. place thermostat. |. Check fluid level in the resi tank with engine and conve running. If fluid level is beModels CO-10,000 and 1) Table |. Trouble Shooting. [7 Symptom Cause Remedy “Full” mark on the dip add enough to bring the up to this mark. (See Symg 2-5. Clutch Slippage. 2-5. Check clutch adjustment graph 7D). 2-6. Operating too long in 2-6. Reduce drive range to low efficiency range. gear to permit increase verter speed. If lower range not av. unit and engine are op fon an overloaded con Reduce load. 26 If outpu is over speeding with 1 wide open, shift into range (more direct-incres toad). Converter will 0: because it is dissipati engine power. 3, Low output horsepower. | 3~1. Engine not putting 3-1. Make a stall test on the out rated power. train with a tachomete nected to the engine, locked, and the highes range ' selected. This Down” test r.p.m. varie engines and machines. ( the nearest Twin Di corporated Branch Office sentative or the Rockfore in Rockford, Illinois. T an r.p.m. means the needs service. Too h 1.p.m. means slippage ex the power train which cr the “clutch and/or cor Check clutch and conver overhaul if necessary. 3-2. Improper fluid in the 3-2. Make certain Twin D converter. corporated approved fl: used. (See paragraph 49) Air in system. 343. See Symptom (2-1). |. Low basic pressure. 3-4, See Symptom (2~2). 4, Excessive Pressure. Piston stuck closed 4-1. Remove pump and free in the relief valve on in the relief valve. charging fluid pump.Hydraulic lorque Converter Table I. Trouble Shooting. Symptom Cause L Remedy 5. Excessive converter | 5~1. Bearing failure. 5-1. Remove and disassemb! noise torque converter and 1 worn or damaged parts. 6. Clutch jumps out of | 6-1. Adjustment too tight. 6-1. Properly adjust clutch. engagement 6-2. Improperly position- 62, Adjust hand lever or link: ed hand lever or link- that engaging collar is i age. tral position after engag is made. 7. Clutch will not re- | 7-1, Warped driving plate 7-1. Remove the torque cor lease assembly. from the engine. Disass the clutch and replace th ing plate assembly. 8. Slipping Clutch. 8-1. Excessive grease in 8-1, Remove the torque cor clutch release ball from the engine. Disass bearing. the clutch. Wash the ¢ plate assembly with v Cleaning agent (non-oil non-inflammable), or rey driving plate assembly. 9. Noisy clutch 9-1, Inadequate _Iubrica- 9-1. Grease bearing as instr tion of clutch release If noise persists, replace ball bearing. ing. 9-2. Worn splines on in- 9-2. Remove the torque con pat shaft and/or from the engine. Disass clutch driving plate the clutch and replace parts. 28. SPECIFICATIONS CHART. Fluid capacity 7 (less volume in cooler and lines) ‘The specifications chart (Table IL.) is a ready source Lubricating oil capacity of general information on the Torque Converter and Converter input oil chamber (end plat: clutch assembly. Refer to it forquick reference data. - i Converter output oil chamber |. 4.5 Table Il. Specifications Dry Weight ce Pressure drop available for heat exchanger Maximum Safe Speed 2400 RPM . 15 psi per 100 input he Fluid temperature (Normal 180-220°F (Max. 250°F) Heat Exchanger Capacity Required Fluid charging pump pressure Industrial Applications... .30% net e Normal Service .... (50-60 psi—Max. 65 psi) Crawler Tractor Service... 40% net e Power shovel service (20 psi)mogels CYU- 1U,UUU and | Down Hill Brake Service Approx. 75% net engine HP (Consult Twin Disc, Incorporated Rockford Works, Rockford, illinois) ndard 1-1/4" Clockwise at input end Cooling Pipe Size... st Direction of rotation Section VII. REMOVAL 29. PRIOR TC REMOVAL. A. Lubrication il System. Drain the oil from the input and output lubrication oil chambers. (See paragraph 220). B. Converter f iuid System. Drain the fluid from the fluid system and fluid filter. (See para- graph 22D). 30. REMOVAL. A. General. Installations vary, therefore, follow the original equipment manufacturers recom- mendations when removing the torque converter. B. Output End. Disconnect and/or remove all equipment from the output end of the torque con- verter. C. Mounting Parts. Remove the attaching parts from the output shaft housing (six hex-head cap screws 1/2-13 supplied by 0.E.M. upon installa- tion). D. Cooling Lines. Disconnect the converter fluid cooling lines at the converter. Protect the openings from entry of dirt E, Clutch Linkage. Remove the clutch ex- ternal operating linkage. F. Engine Connection. Attach a hoist to converter assembly. Remove the cap screws or nuts furnished by the 0.E.M. to secure the clutch hous- jing to the engine. Remove the clutch housing top cover plate and the hand hold cover from the lower right side of the clutch housing. By reaching through these access holes disconnect the clutch bearing grease hose at the clutch housing and free the fork from the sliding sleeve trunnion blocks, as the con- verter assembly is pulled rearward from the engine flywheel. Remove the converter assembly. G. Cluich Assembly. Remove t furnished twelve 3/8-16 N.C. x 1-1/2 he: screws which retain the clutch pressure j and clutch assembly to the engine flywhee the clutch assembly Section VIII. DISASSEMBL xternally clean the converter assembly w or steam cieammg equipment. Choose a « ‘lighted, dust-free area for cisassembly. procedures outlined below ss a guide for bly of the unit. 31. INPUT. INPELLER, AND FREE GROUPS OF PARTS. A. Remove the cover plate retain (fig. 66, 20) lockwashers (19) plate (18), (17). Remove the fluid pump inlet line ( and discharge line (2) from the pump fi plate, and reserve tank fittings. Disc temperature gauge from the turbine housing Remove the six hex-head cap screws (fig & 28) securing the filter and reserve t turbine housing assembly and vemove the reserve tank assembly. B. Place the converter assembly able work bench firmly blocked up with housing facing up. Remove the inbe oil nipple (ig. 68, 10) and gauge (9, feom the housing. Remove the four hex-head cap s and washers (27) securing the fluid pump sprocket housing and end plate assembl ‘the fluid pump (25) and gasket (24). D gasket. Remove the drive screws (fig. 6 instruction name plate (21) only if the 1 of parts is necessary. Remove the drive s and engine oil plate /23) only if required. C. Remove the four sprocket hot head retaining screws (fig.68, 13) and we Remove the sprocket housing (15) and g from the end plate. Discard the gasket. D. Remove the end plate drain p (fig. 66, 32) and cap (31). Remove the cooler inlet pipe flange from the end plat 37) by removing the two hex-head cap s and washers (38). Remove and discard (36).E. Remove the twenty-four hex nuts (fig. 66. 34) and lockwashers (33) retaining the clutch hous ing to the end plate and turbine housing assembly (fig. 68, 20) and remove the clutch housing with attached parts. Use three pusher screws in the holes provided in the end plate and separate the end plate from the turbine housing assembly. Remove the end plate assembly (jig. 68, 11) with attached parts with a suitable hoist. Gather up the 14 freewheel rollers ‘fig. 69, 4) which drop free. Remove and discard the ring gasket (fig. 68, 12) from the end plate. F. Loosen and remove the two clamp bolts (fig. 66, 13) lockwashers (12) and key washers (17) which secure the fork (10) to the operating shaft (41). Remove the operating shaft (41) and remove the operating fork (70) from the clutch housing. Re- move the grommets (14), (25), (27), and (29). Remove the lifting eye (76) retaining nut (28) and remove the lifting eye (16). G. Set the end plate assembly on the bench (blocked up) with the freewheel end facing upward, Unlock the freewheel retaining shroud nut (fig. 69, 8) by removing the socket-head setscrew (9) from the nut. Loosen and remove the shroud nut (8) from the input shaft with special tool T-11899. Remove the nut lockwasher (7) from the input shaft. BEARING LOCK NUT SPECIAL TOOL T-N1899 YMPELLER WHEEL Figure 9. Removing Bearing Lock Nut with Special Tool T-11899. Myaraulic torque Converter Remove the freewheel cage springs (fig. 6 (10) from the cage and freewheel cam. Ret freewheel cage (5a) from the freewheel cam the freewheel cam (3) and roller bearing ¢ (2) from the input shaft. Remove the roller (2) from the freewheel cam. Remove the two snap rings (1) from the freewheel cam, on placement of the parts is necessary H. Turn the end plate assembly over 1, Remove the six hex-head cap scr 66, 6) and lockwashers (5) retaining the sleeve cartier to the end plate. Use tw screws and separate the carrier from the e1 Remove the cartier (1) and input shaft (4) a sembly from the end plate. Remove and dis gasket (2) from the end plate or carrier. INPUT SHAFT Figure 10. Using Pusher Screws to Separate from the End Plate. J. Remove the setscrew (fig. 68, 1) impelier ball bearing lock shroud nut (2). Lo remove the shroud lock nut (2) from the imp with special tool T-11896. K. Remove the master link pin in the fluid pump drive chain and remove the chain 6). Remove the sprocket (19), fluid pump dri (21) and bearings (18) and (22)moaeis CY-lu,v¥uyU and Ir L. Remove the impeller wheel from the end plate by supporting the end plate and pressing the impeller wheel (fig. 68, 33) hub downward through the end plate, chain sprocket (4) and impeller wheel bearing (7), Remove the forward section of the split ball bearing inner race (7). M. Remove the “O” ring (fig. 66, 9) from the input shaft (4), Remove the rear external snap ring (8) fromthe input shaft. Support the carrier and press the input shaft (4) and bearing (7) from it, toward the rear N. Remove the forward bearing retaining ex- ternal snap ring (fig. 66, 8) from the input shaft and press the bearing (7) from the shaft with special tool T-11902. 0. Press the oil seal (fig. 66, 3) from the sliding sleeve carrier with special tool T-11913. T1190: P. Turn the end plate so the fluid seal assem- bly side is upand remove the six 12 point cap screws (fig. 68, 30) which retain the fluid seal carrier to the end plate. Turn the end plate over and press the impeller wheel bearing, seal carrier, and seal as- sembly from the end plate. Remove the bearing (7), seal assembly with carrier (29), and gasket (28). Dis- card the gasket. Remove the two slotted head ma- chine screws (fig. 69, 14k) and clips (14h) from the fluid seal carrier. Remove the seal nose piece (14a), springs (146), retaining washer (14c) shaft seal (I4e), and garter spring (14d) from the carrier. Remove the seal (14g) from the carrier (140). Q. Remove the mating ring washer (fig. 68, 32) and carbon mating ring (31) from the impeller wheel hub, R. Remove the fluid fitting (fig. 72, 4) from the end plate. S. Remove the bearings (fig. 68, 18, 22), sprocket (19), and key (20) from the fluid pump drive shaft (21). 32. OUTPUT AND TURBINE GROUPS OF PARTS. A. Remove the seal drain line fitting jam out (ig. 70, 19) and temove the plain washer (20) and ting gasket (21). Discard the gasket. B. Remove the oil level gauge (fig. 70, 8). Figure 11, Removing Input Shaft Front BaSUDING SLEEVE CARRIER Figure 12. Removing Input Shaft Oil Seal. C. Remove the twelve hex-nuts (fig. 70, 15) ‘and washers (14) from the studs retaining the output housing to the converter housing. Remove the studs (13) only if replacement of the parts is necessary. D. Remove the output housing (fig. 70, 16) ‘and ring gasket (25) from the turbine housing assem- bly. Discard the ring gasket. The output shaft will remove with the housing. E. Remove the two socket-head headless, Cup point set screws (fig. 70, 36) from the output housing. Remove the governor drive adapter (30) from the output housing. Remove pipe plug (35) from output housing. F. Remove the spacer (fig. 70, 26) from the output shaft. Remove the snap ring (5) from the out- put housing (16). Remove the three pipe plugs (17) Myaraulic torque Converter from the output housing and tap the outer race removing the output shaft and bearing output housing. G. Pull the governor drive gear (fig. from the output shaft. Remove the Woodruff from the output shaft. Remove the spacer ( the output shaft. H. Remove the oil seal (fig. 70, 7) output housing. |. Use special tool T-11912 and spiral gear shaft (fig. 70, 32) and plain bea: from the output housing (16). Remove the ey plug (34). Use special tool T-202315 and p flanged plain bearing (33) out of its bore. J. Use special tool T-11914 and p spherical roller bearing (fig. 70, 6) from the out, K. Remove the lifting eye assembly 10) from the output housing only if replace the parts is necessary. L. Unlock the (turbine wheel hub) lock nut (fig. 69, 24) or remove the setsci from the lock nut. Remove the lock nut (24). the lock washer (23) from the turbine whee! t move the turbine wheel assembly (11) from 1 bine housing by supporting the housing ( pressing on the output end of the turbine wt spline. This will result in separation of the wheel assembly (11) from the rear fluid seal bly (14) and double-row ball bearing (22). M. Tum the turbine housing over output side is downward and remove the point cap screws (fig. 69, 16) which retain t cartier to the turbine housing. Tap on the row ball beating outer race and remove th cartier (14f), seal gssembly (14), and dou ball bearing (22) from the turbine assembly h Remove the fluid seal carrier gasket (15) f turbine housing and discard the gasket. N. Remove the mating ring washer (, 12) and carbon ring (13) from the hub of the wheel assembly. 0. Remove the two slotted-head n screws (fig. 69, 14k) from the fluid seal cart remove the eight compression springs (14 Clips (14h), and nose piece (14a) from the flt carrier. Remove the oil seal (14g) from themoaelis CYU- 1U,UUU and II P. Remove the fitting (fig. 70, 24) and flexi- ble hose (23) from the turbine housing assembly, 33. 17-INCH OVERCENTER “MASTER” CLUTCH GROUP OF PARTS. A. Remove the driving plate and clutch a: sembly from the engine flywheei. B. Loosen the hex-nead cap screw fie 67, 8b) retaining the ring avjustmert lock and locsen the adjusting ring (7). C. Use special toot T-206769 and -emove the pressure plate release springs (fig. 67, 24) from the clutch cover plate. D. Remove the external snap ring (fig. 67 15) retaining the release collar (1/1 to the sliding sleeve (12). Figure 13. Removing Pressure Plate Return Springs with Special Tool T-206769. E. Pull the sliding sleeve (ig. 67, 12) from the release collar (11). F. Remove the pressure plate (fig. 67, 3) and attached parts from the cover plate assembly. Re- move the adjusting ring (7) from the cover plate (8). G. Remove the four roll pins (fig. 67, 9) collars (10), and headed pins (23) which retain the lever links (6d) to the sliding collar (11). Remove the collar (11). H. Remove the four roll pins (fig. 67, 5) in the pressure plate levers (6a) which locate the lever pivot pins (4) and levers (6a). Center punch mark the closed end of each of the four of the eight closed-end bearings (2). Drill a 1/4-inch hole at each center punch mark. Use a straight punch through the 1/4-inch hole to tap out the four undri ings (2) and then tap out the four lever 4 and drilled bearings (2). Discard the fo bearings (2). Remove the levers. Set the Ic vise one at a time and remove the four (6b) and collars (6c). Remove the four he (Ge) and four links (6d) from the levers 1. Remove the internal snap ring (fi from the sliding sleeve and press the slidi ball bearing (13) from the sliding sleeve the two cotter pins (18) from the slidii irunnions and remove the wo shifter bic Remove the flexible nose (17) and 45-deg (16) from the sliding sleeve (12). J. Remove the hex-head cap screw 8b), foll pin (Sd), and lock (8c) from cover plate only if replacement of the par essary. 34, EXTERNAL PARTS. A. Remove the lifting eye (fig. 70 the output housing. B. Remove the drain valve (fig. 69 the converter housing, C. Remove the four hex-head cap sc 71, 39) and washers °;8) which retain the cutlet) pipe flanges 37) t2 the converte and end plate. Remove the flanges (37) ar (36). Discard the gaskets (36) D. Remove the converter drain plu 26) E. Remove the two drive screws (fi securing the lubricating oil plate (11) to housing only if replacement oi the parts sary. 35. FLUID SYSTEM GROUP OF PARTS. A. Remove the four hex-head cap sc 71, 13), lock washers (3), and nuts (2) wh the filter assembly to the bracket (6). Ri (inlet and outlet) fittings (fig. 72, 9) from (fig. 71, 4). Remove the temperature gaugi pressure gauge (17) from the bracket (6) gauge mounting bracket grommets (12) bracket.B. Remove the four drive screws ifi2 71 8) which secure the instruction plate (7/ to the oracket (6) and remove the instruction plate only if repla-e- of the parts is necessary. C. Pemove the fluid ioval gauge ‘fie. 71, 1) from the reserve tank (29). Remove ite two dive screws (18) securing the fluid late (191 te t reserve vank and remev2 the fluid piste cay 1. tee replacement of the na1:s is aeceseay sterove the ten hex mits (26) ar washers #3.) which cover plale (22) to the reserve tani. F cover plate /22) ond yasket /23.. “iscard vie g.skst, Reimove th> (output seal drain) ‘ting ig 72, 19) from the reserve tank. Remove the flexibi2 ‘lose (12) the fitting, Remove the (rea: seal iain) stand pige (fig. 72, 25) and fitting (23) from =1e reserve Remove the (front seal dreisi) stane pipe (25: siting (24) from the reserve tank. Remove the (fluid pemp suctior Line) fisting (32) fron the i2- serve tank, Remove the (fl id pump suction filter screen) close nipple (31) and serzen "2; from the reserve tank 1D, Renove the orifice Fite: (ig. 72, $2) from the reserve tank. Remove the close coupliag (31) from the reserve tank. Remove the elbos (22) from the orifice fuiter. Remove the orifice filter head (33a), filter element (3c), and gasket (336) from the filter body (33d). Discard the gasket 33). Section IX. CLEANING AND INSPECTION 36. GENERAL. A Gi’ Seals. Replace all 0:1 seals. B. Gastets. Replace all gaskets. C. Ring Gaskets. Replace all ring yaskets D. Fivid Seat Assemblies. Replace toe fluid Sea's with the seal service kit assemblies, which are available E. Fluid Filter Element. Replace tluid filter element with service kit assembly. 37. CLEANING. A. Ball and Rotler Bewings. Use vtaniard maintenance procedures to clean the ball asd rollei bearings. nyarauiic torque Converter ee B. Fluid Gear Pump Assembly. U fresh cleaning agent when flushing the flu assembly C. Fluid Seals, The nose pieces anc mating rings are precision machined and lz extremely close tolerances. A nev service Placement seal should always be ins‘alle. the conveiter is disassembied and the flu ate removed. D. All Other Parts. Thoroughly ¢ other parts with a suitable cleamng ager cleaning, dry with compressed air. Lubric machined surfaces with clean oil. Exami part aiter cleaning to make certain all foreig has been removed. 38. INSPECTION. A. Ball and Rotler Bearings. Use ¢ naintenance procedures to inspect the b oiler beerings. B. Castings Inspect all castings for Fepiace a cracked casting. Inspect all bearin xd mounting faces for wear, grooves, scratch Remove buns and scratches with a crocu: fire file, or stone. Inspect tapped holes for é theads Case damaged threads with a use: the comrext size. Replace all castings that be repaired. Sslined Parts Inspect all spline ser worn, twisted, chipped, or burred splin pla‘e a spliaed part that cannot be repaired D. Tweaded Parts. Inspect all t Farts for damaged threads. Repair damaged With @ threed file or a fine three-cornered fi place a thrended part that cannot be repaired E. Temperature Gauge Assembly. the temperature gauge assembly for damay place a damaged temperature gauge assembly F. Prossure Gauge Assembly. inspt Twssure gevge assembly for damage. Rey demaged pressure gauge assembly. G. Clutch Assembly Inspect the chiving plate for glazing, checked, broken-o tions, and other facing damage. Replace ad clurch driving plate. Inspect the flywheelmoaels VU-1U,UUU ana I face surface for glazing, scored. and/or scuffed condition. Replace a damaged flywheel. Inspect the clutch pressure plate surface for same defects mentioned for flywheel. Replace a damaged clutch pressure plate Inspect the clutch adjusting ring surface for brinelling at roller contact areas. Re- place a damaged adjust’ng ring When the clutch facing material is worn to a point where no more ad- justing ring movement will permit c.utch engagement ‘without slipping, the clutch faced driving plate must be replaced. H. Impeller Wheel, Turbine Wheel, and Tw: bine Housing Inspect these assem- blies for loose, bent or broken blades. Replace a damaged assembly Assemblies. Section X, ASSEMBLY NOTE (Torque values given are for clean, dry threads.) (Cleanliness during assembly is of ut- ‘most importance.) (Pre-lubricate all moving and machined ‘mating parts with light oil.) 39. OUTPUT SHAFT AND HOUSING GROUP OF PARTS. A. Use special tool T-11897 and install the oil seal (fig 70, 7) into the output housing. SPECIAL TOOL T.897 Figure 14. Installing Output Shaft Rear Seal with with Tool T-11897 B. Instail the oil level gauge nippl 9) into the output housing. Install the thre: pipe plugs (17: into the output housing C. Install the the output housing ‘fing eye (x 0 D. Use special too T-202315 a the spiral gear shaft f'anged bearing ( into the output housing FLANGED BE Figure 15. Installing Flanged Bearing 7-202315 Install the spiral gear shaft (32) inte ing and flanged plain bearing. Install the ing (31) over the spiral gear shaft and into bearing bore of housing with the specs 208541. E. Install the cable adapter (fig. 7 the spiral gear shaft in the output housi the adapter (30) with two cup point set s 1/4.20 x 1/4, Tighten the screws to torque. F. Install a new expansion plug (f in the output housing, using a non-harden in the bore to provide positive seal.PLAIN BEARING Figure 16. Installing Plain Bearing with Tool T-208541. G. Use special tool T-11914 and press the spherical roller bearing (fig. 70, 6) onto the output shaft (1) against the shoulder provided. PRESS FORCE HERE SPECIAL TOOL TaI914 SPHERICAL RIN ‘ourpur SHAFT Pigure 17. Installing the Spherical Roller Bearing on the Output Shaft with Tool T-11914. Install the spacer (29) onto the output shaft. Install the spiral gear (locating and drive) key (28) into the output shaft. Use tool T-11915 and press the spiral ear (27) over the key (28) (index groove) and against the spacer (29) on the output shaft. SPECIAL TOOL TM915, ‘ourput WoopRUFF KEY, srirat cean SHORT SPACER, Pigure 18. Installing the Spiral Drive G Tool T-11915. H. Install the output shaft with parts into the output housing. Tape the key of the shaft and use care when passing | through the oil seal so seal damage is pi Press on the spherical bearing outer raci piece of steel tubing until bearing botton output housing bore. Install the internal (fig. 70, 5) to retain the bearing in housing the spacer (26) on the output shaft against gear. I. lustall the twelve studs (fig. 70, the converter housing. 40. CONVERTER HOUSING GROUP OF PA A. Use tool T-11901 and install the row ball bearing (fig. 69, 22) into the housing. Press the bearing into the hous the rear until it protrudes approximately 1 into the converter housing. This will p pilot for the fluid seal carrier and carrier gat B. Install the fluid seal carrier gas 69, 15) over the double-row ball bearing a the oil passages and screw holes proper gasket should be briefly pre-soaked in c fluid. Use special tool T-11898 and press seal (14g) into its bore on the bearing sid fluid seal cartier. The lip of the oil sea face the bearing (22).MOGEIS LYU-1U,UUU ana II Figure 19. Figure 20. C~) TURBINE Be ASSEMBLY HOUSING Installing the Double Row Ball Bearing into the Turbine Assembly Housing with Tool T-11901. SPECIAL TOOL yna98 SEAL CARRIER Installing the Lip Type Oil Seal with 7-11898. Keep the nose piece and mating carbon r fluid seal assembly well protected throt assembly of the fluid seal. These parts « to extremely close tolerances (12 milliot inch). Lay the fluid seal carrier on a cle: oil seal side downward C. Place the garter spring (Jig. 6 the rubber element (//e) and install the r ment in its bore in the seal carrier, gat side up. Lubricate this side of the rubbi with clean oil. Install the retaining was (or spring carrier), shoulder side down in bore of the rubber element. Fill the sprin bores in the nose piece with grease. compression springs (146) in the gre counterbores. Lubricate the skirt of the 1 with clean oil. Invert the nose piece and in the seal carrier. Exercise care in en skirt of the nose piece into the lip of element. Line up the clip slots in the r with the clip slots in the seal carrier. Cor nose piece (14a) to the carrier (14f) and two clips (14h) and screws (14k) retainin, piece to the seal carrier. Check for free of the steel nose piece. Tighten the sci to 11 Ibs.-ft. torque. D. Install the fluid seal assemt turbine housing assembly (fig. 69, 20). | fluid seal assembly to the turbine ho six 12 pt. cap screws (16) 3/8-16 x 1. T screws to 37 Ibs. ft. torque. The bearin, provide a pilot for the gasket (15) and s during assembly. E. Place the rubber (carbon ma washer (fig. 69, 12) on the carbon mating The flat side of the washer bears against th of the mating ring. Lubricate the bore of 1 wheei, which will receive the carbon m and washer with a film of clean oil. F. Hand press the mating ring ((i and washer (12) into the bore on the turb Make sure they are seated properly. G. Make sure the sealing surfaces o piece (fig. 69, 14a) and mating ring (13) and smooth. Lubricate the sealing surf clean oil H. Install the turbine wheel witk Parts into the turbine housing by usir and lowering the turbine housing onto tHydraulic wheel assembly. Guide carefully through the fluid seal assembly TURBINE WHEEL HUB TURBINE ASSEMBL HOUSING Figure 21. Installing the Turbine Wheel Assembly. I. Install the bearing lock-nut washer (fig. 69, 23) and the bearing lock nut (24) onto the turbine wheel. Use special tool T-11896 and tighten the lock nut securely (900 Ibs.-ft. torque). Lock the nut with a tab from the lock washer (early production) or a setscrew (25) (ater production). (See paragraph 40. J. Install the bearing retainer (fig. 70, 3) and gasket (jig. 69, 22) to the rear of the converter hous- ing. Secure the retainer with six 12 pt. cap screws fig. 70, 4) 3/8-16 x 3/4. Tighten the screws to 38 tbs.-ft. torque. K. Install the hose fitting (fig. 70, 24) into the seal drain outlet on the turbine housing. L. Use a hoist and suspend the output hous- ing with attached parts over the turbine housing. Install the flexible hose (fig. 70, 23) into the fitting (24) in the turbine housing and install fitting (22), through the hole provided in the output housing. lorque Converter Install ring gasket (21). plain washer (2 nut (19) to fitting (22) on the outside 0 housing. Lower the output housing until hose (23) can be attached to the fitting the flexible hose to clear the spiral drit gear. Lower the output housing with att onto the turbine housing indexing the shaft with turbine and secure it with twe (14) and nuts (15) 3/8-24. Tighten the Ibs.ft. torque. 41. END PLATE AND IMPELLER C PARTS. A. Use special tool T-11898 and type oil seal (fig. 68, 8) into the fluid s (See paragraph 40 for details on fluid seal Lip of seal to face the bearing (fig. 68, 7 B. Install the garter spring (fig. 6 the rubber element (14e). Install the rub (14e) into the fluid seal carrier. Install retainer washer (I4c) into the bore of element in the carrier. Assemble the eig sion springs (146) between the nose pit seal cartier. Compress the springs and two clips (14h) and slotted machine si into the carrier through the clips. Tigh! screws to 11 Ibs.ft. torque. C. Install a mating ring (fig. 6 washer (32) on the impeller hub. D. Install the outer ball bearing 1 bly (fig. 68, 7) into the end plate bearit stall the rear section of the split inner ra E. Install and properly locate the carrier gasket (fig. 68, 28) into the em install the seal carrier (29) with atta Secure the seal carrier assembly to th (11) with six 12 pt. cap screws 3/8-16 x 3 the screws to 38 Ibs. ft. torque F. Set the impeller assembly on with the hub section upward. Lower th assembly onto the impeller wheel asse care as the impeller hub passes throu; assembly G. Install the split ball bearing forward section (fig. 68, 7) into the en outer bearing race.Models CU-10,000 and I Figure 23. Installing Impeller Wheel Assembly into the End Plate Assembly. Figure 24. Installing Split Bearing Inn H. Use special tool T-11900 and inner race forward section to butt af section of inner race and balls of the ou race. Figure 25. Pressing Inner Bearing Race inte1, Install sprocket key (fig. 68, 5) into the impeller hub. Push sprocket (4) onto the hub, indey- ing keyway with key (5), Install the lock nut washer 3) and install the lock nut (2) NOTE There were two type lock washers and lock nuts used. The early type was a tab type. The late type is a setscrew type. They are interchangeable as pairs; that is, washer and nut. The late type nut can be used with either tab type lock washer or setscrew type lock washer. Tighten the lock aut with special tool T-11896 to 900 Ibs. ft. torque. Then line up a tab groove (old style) or a setscrew hole (new type) by further tightening the nut. Lock nut in place with a tab or — PLATE Sa Figure 26. Tightening the Bearing Lock Nut with Tool T-11896. J. Use special tool T-11903 and install the front bearing (fig. 68, 22) on the front section of the pump drive shaft (27). Install the pump chain sprocket key (20). Install the chain sprocket (19) (hub to the rear) indexing keyway with key. Use special tool T-11903 and install rear bearing (18) on the pump drive shaft against the sprocket (19) K. Install a new seal (fig. 66, 3) in sleeve carrier with special tool T-11897. Use special tool Hydraulic Torque Converter 7-11902 and install the ball bearing (7) on shaft (4). Press bearing inner race age shoulder on the input shaft. PRESS RAM T1903 BALL BEARING DRIVEN SPF Pigure 27. Installing Bearing on Pump Dri SPECIAL TOOL y-11902 INPUT SHAI JALL BEARIP INPUT SHAFT Figure 28. Installing Bearing on Input Sh 7-11902.models LU- 1U,UUU and I Install the extemal snap tings (8) on the input shaft. Install “O” ring (9) on the input shaft INPUT SHAFT FREEW! L. Carefully install the input shaft assembly into the sleeve cartier (fig. 66, 1). Use a press and tool T-11902 to press the shaft and bearing into the sleeve carrier, M. Install gasket ((ig. 66, 2) on the end plate aligning the holes properly. Install the sleeve carrier and the input shaft into the end plate (jig. 68, 11) and impeller (33). Secure the cartier to the end plate with six hex-head cap screws ‘fiz. 56, 6) 3/8-16 x 1/1/4 and lock washers (5). Tighten the screws to 38 Ibs. ft. torque 42, FREEWHEEL GROUP OF PARTS. FREEWHEEL ROLLER BEARING | IMPELLEI A. Install the two external snap rings (fig. 69, 1) into the freewheel cam (3). Set the end plate assembly on supports with ‘the rear section of the Figure 30. Installing the Freewheel B input shaft facing upward. Use special tool T-200448 ‘and install the freewheel cam on the end of the input C. Install the two roll pins (sig. shaft. Use care when indexing the splines the holes provided in the freewheel cam I D. Install the freewheel cage (fi Install the five freewheel bumper sprin two cage return springs (10). Install the Jock nut washer (7) and lock nut (8). T to 290 Ibs. ft. torque minimum with too Align a hole in the lock washer with a se Tighten the setscrew to 11 Ibs. ft. torque INPUT SHAFT BEARING Lock Figure 29. Installing the Freewheel Cam. B, Install the freewheel roller bearing (/ig. 69, 2). The beating is marked on the rear side. The rear side must be up or toward the turbine. Push the bearing down to the snap ring. Figure 31 Special Roller Tool in |E. Select an “O” ring from parts stock which will fit around the freewheel cage under tension. Install the “O” ring on the freewheel cage and slide rollers (fig. 69, 4) in the cage pockets below the +0” ring. Move the “O” ring near the shaft rear end section of the rollers and install the special snare tool T-11925 around the center of the rollers. Thread the end of the wire through the blades of the impel- ler and to the outside F. Install a ring gasket (fig. 85 rear flange surface of the end plate. 12) on the G. Set the turbine housing and attached parts on supports with the turbine facing upward. Attach a hoist to the end plate and attached parts so the freewheel faces downward. The end plate and turbine housing parting flange surfaces must be as square as possible. Remove the “O” ring after rechecking the snare tool position. Be sure rollers are located on the cam to their lowest setting H. Slowly lower the end plate assembly with attached parts indexing the freewheel with the tur- bine hub freewheel outer race. Do not use force! Gravity should be all that is required to assemble the two assemblies. Turning the input shaft clock- wise will assist the rollers entering the outer race. When the parting flanges are approximately 1/2-inch apart, and you are certain the rollers have entered the outer race, remove the snare tool with a sharp tug. Finish lowering the end plate assembly to mate parting surfaces. 43. INPUT GROUP OF PARTS. A. Set the clutch housing (fig. 66, 15) in place over the studs on top of the end plate (fig 68, 11) and secure the three parts together with twenty-four 3/8-24 hex nuts (fig. 66, 34) 3/8 lock washers (93). Tighten the nuts to 38 Ibs. ft torque. NOTE Alignment of the three surfaces is im- portant B. Install the drive sprocket and shaft as- sembly for the fluid pump (fig. 68, 25) into the end plate. Install internal snap ring (23) in the end plate. Assemble the roller chain (6) and connect the coupler link. Hydraulic Torque Converter C. Install the sprocket housing gash 68, 16) and housing (15) over the two dow (17), Secure the housing (15) to the end ple four hex-head cap screws (13) 3/8-16 x 3/4 washers (14) 3/8 D. Install the fluid pump gasket (fig to the end plate and sprocket housing. Ins fluid pump (25) indexing the drive tang in | of the drive shaft. Secure the fluid pump to plate and sprocket housing with four hex-hi screws (26) 5/16-18 x 3/4 and lock washe ‘Tighten the cap screws to 21 Ibs. ft. torque. E, Install the pipe flange (fig. 71, § gasket (36) washers (38) and two hex-he screws (39) 3/8-16 x 1-1/4. Tighten the sc 38 Ibs. ft. torque. F. Install the drain pipe coupling ( 32) and cap (31) to the end plate. G._ Install the 5/8 x 1-3/4 eye bolt ( 16) and 5/8-11 Esna nut (28) in the clutch h Tighten the nut to 175 Ibs. ft. torque. H. Install the four grommets (fig. 66, 27, and 29) in the clutch housing. I. Install the hand hole plate (fig and gasket (35). Secure the plate with si slotted head machine screws (37) 1/220 Tighten the screws to 11 Ibs. ft. torque. J. Install the pipe nipple (fig. 66, 3 3 x 1/4 in the end plate. Tighten the nippl Ibs. ft. torque. Install the pipe cap/31) to the Tighten the cap to 47 Ibs. ft. torque. K. Install the name and instructior (fig. 66, 21) to the clutch housing. Secure th to the housing with four drive screws (22) L. Install the oil level gauge nipple () 10) through the grommet (fig. 66, 14) and i end plate. M. Install the flexible hose fitting (/ 20) into the clutch housing from the inside, | hole provided. Install the lock washer (21) fitting. Install the jam nut (22) on the fitting. the lubrication fitting (fig. 66, 26) into th fitting.models CU- 1U,UUU and II CLUTCH HOUSING PIPE NIPPLE PIPE WRENCH SLIDING SLEEVE CARRIER INPUT SHAFT Figure 32. Screwing the Oil Level Gauge Nipple into the End Plate. NN. Install the two operating shaft bearings (fig. 66, 39 & 43). Hand pack the bearings with grease and use the special tool T-203713 to press them in place in the clutch housing, y-203713 CLUTCH HOUSING Figure 33. Installing Operating Shaft Bearings with Tool T-203713. Use tool T-203713 and install the dust s 66, 38 & 40). ¥-203713 cLurcH Ho Pigure 34. Installing Operating Shaft Du 0. Carefully insert the operating s 66, 41) through from either side of the clu ing. Hold the fork (10) straddle of the slidi carrier and thread the operating shaft th fork. Align the keyways in the shaft with t each bolt boss location on the fork (70). I key washers (11) and hex-head cap scr 1/213 x 2 and washers 1/2-inch spring in the slot of the fork and keyway of the sure cap screw heads face toward the re: verter direction, Tighten the cap screws 1 ft, torque 44. FLUID SYSTEM GROUP OF PARTS. A. Install the filter screen (fig! 77 the reserve tank. Install fittings (34 & 36) Locate the stand pipes parallel with ang side of reserve tank. Install the front and drain, stand pipes (35 & 25) into the res parallel with the angular side of the tan the cover gasket (23) and cover (22) to 1 the reserve tank. Secure the cover with 1 Jock washers (21) and ten hex nuts (26 Tighten the nuts to 38 Ibs. ft. torque. Inst verter fluid identification plate (19) secu the cover plate with two drive screws (1! the close pipe nipple (31) 1/4-inch, into tk tank. B, Install the orifice filter head (fig. element /33c), and gasket (335) into the orilheres Rat C. Install the orifice body ‘fie. 77, 33a) into the close nipple in the reserve tank. Tighten the filter securely ending with the threaded part facing downward D. Install the 1/4-inch square head pipe plug lig. 71. 390 in the bottom of the reserve tank. E. Install the temperature gauge sensing bulb ‘ig. 71. 161 into the threaded hole provided in the turbine housing assembly ‘fig. 69. 201, Coil up the surplus gauge tube and tie the coil with strong cord or safety wire F. Install the fluid pressure and temperature gauge grommets (fig. 71, 12) into the filter bracket G. Install the elbow ifie. 72. 6) into the oil Pressure gauge ‘fig. 71. 17). Elbow should face downward, when tightened. Install the flexible hose (tig. 72, 7) into the elbow (6) of the pressure gauge (tig. 71, 17) H. Install the pressure gauge and hose into the forward gauge mounting of the filter bracket. I, Install the inlet elbow (fig. 72, 5 into the fluid filter (fig. 71, 4) inlet port. Install the “tee” fitting “jig. 72. 97 into the filter outlet. J. Install the filter assembly ‘fig. 71, 4) to the biacket (6) with four hex-head cap screws (13) 3/8.24 x 3/4 four lock washers (3), and four nuts 3/8-24. Tighten the nuts to 38 Ibs. ft. torque. K. Install the reserve tank to the turbine housing assembly (fig. 69. 20) with two hex-head cap screws (fig. 71. 15) 3/816 x 3/4 and two lock washers (14). Tighten screws finger tight. Install the bracket (6) with attached parts to the turbine assembly housing, using two hex-head cap screws (15) 3/8-16 x 3/4 and two lock washers (14). At the time that the bracket is being mounted the tempera- ture gauge should be slipped into its mounting grommet. Slide the reserve tank bracket beneath the gauge bracket (6) against the turbine housing as- sembly and align the holes for the two hex-head Cap screws (28) 3/8-16 x 3/4. Install thecapscrews and lock washers (27). Tighten all six hex-head cap screws, securing the reserve tank and filter bracket assemblies to the converter housing, to 38 Ibs. ft torque. Hydraulic lorque Converter L. Install the rear seal drain elbow / 11) and reducing bushing (10) into the reser. Install the rear seal drain elbow (73) in the below the output housing (fig, 70, 161. Cont flexible hose (fig. 72, 12) between the elbo and (13), M. Connect the pressure gauge flexib (fig. 72,7) from the gauge to the “tee” fitting bottom of the fluid filter. N. Install the oil pressure supply elbc 1) into the end plate 0. Install the tube assembly ‘fig. 72 the filter “tee” fitting through the grommet in housing to pressure supply elbow P. Install the elbow ‘fig. 72, 141 it front seal drain port in the end plate. Inst front seal drain elbow ‘fig. 71, 32) in the 1 tank, Q. Install the tubing assembly (fig. from the elbow (14) through the grommet in housing to elbow ‘fig. 77, 32) in the reser (29), R. Install the suction line elbow ‘fig into the reserve tank. S. Install the suction tubing (ig. 72, 1 the pump inlet fitting (1) through the gromme clutch housing to the suction elbow ‘ig. 71 the reserve tank. 45. CLUTCH ASSEMBLY GROUP OF PARTS A. Set the clutch pressure plate on a face downward and install the four pressure levers as follows: Install a headed pin (/ig. 6 and link (6d) to each of the four pressure plate Secure the link and pin with a collar (6c) and pin (66) 1/8 x 5/8. B. Install a closed end needle roller b (fig. 67, 2) in one beating boss of the pressure Insert a lever pivot pin (4) to prevent colle of the bearing retaining shell while tappir bearing into the flush position with the lever of the bore. Usea piece of bar stock slightly s in O.D. than the bearing bore.Models CO-10,000 and 1) \\ BAR STOCK, PRESSURE PLATE Figure 35. Installing Lever Pin Needle Bearing. LEVER PIN CLOSED-END NEEDLE BEARING PRESSURE PLATE Figure 36. Proper Location of Closed-End Needle Bearing Tap the bearing with the bar stock and hammer until it is flush with the lever side of the bore. (Figure 37). BAR STOCK LEVER PIN CLOSED-END NEEDLE BEARING PRESSURE PLATE LINK AND LEVER ‘ASSEMBLY Figure 37. Installing Lever Pin Closed-End Needle Bearing. Install the other three levers “tig. 87. 6 same manner. D. Install the four roll pins jig. 83 7/8 in the pressure plate levers ‘éa). Ali pin hole and groove in the lever pin ‘1. U: tool T-209975 and start the pin into its he installing the pin with a straight punct should be located so that it fully locks is pin groove: Figure 38. Installing Roll Pin in Pres. Lever with Too! SLIDING SLEEVE Figure 39. Installing Sliding Sleeve Balnmyaraquiic { Install the ball bearing ‘fig. 67, 13) into Ae aa. E the sliding sleeve (12) with a press and special tool T-11907. Install internal snap ring (11) to retain the ball bear- ing (13) in the sliding sleeve (12) F. Use tool 7-11907 and press the sliding collar and the sliding sleeve assembly together. torque Converter J. Set the cover plate assembly pressure plate assembly. Be sure the lev: are on the outside diameter chamfer of the ring ‘fig. 67, 7) and the lever pivot are with the openings provided in the cover a K. Use tool T-206769 and install release springs (fig. 67, 24 between the plate and clutch cover assembly (6). CLUTCH RELEASE BEARING COLLAR Figure 40. Assembling Sliding Sleeve Collar and Sliding Sleeve Assembly Install the external snap ring (fig. 67, sliding collar to retain the ball bearing 15) into the G. Set the sliding sleeve and collar assem- bly in the center atea of the pressure plate and lever assembly. Index each lever with its connect- ing fork section on the sliding collar. Secure the four lever links to the sliding collar with four headed pins (fig. 67, 23), collars (10), and roll pins (9) 1/8 x 5/8 H. Install the adjusting ring (fig. 67, 7) into the cover (8). Screw the adjusting ring into the cover with the flange toward the flywheel side of the cover. L. Install the ring adjusting lock (fig. 67, 8c) hex-head cap screw (8b) 3/8-16 x 1, and roll pin (8d) 3/32 x 9/16 into the cover assembly. SPECIAL T "7.206769 RELEASE SPRIN( Figure 41. Installing Clutch Release Spr L. Install the two shifter blocks fig onto the sliding sleeve trunnions (12). In two cotter pins (18) to retain the shifter M. Install the 1/8 x 45 degree elbo (fig. 67, 16) into the sliding sleeve (12). In flexible hose (17) into the 45 degree elbo (6). N. Coat the spline and machined of the hub section of the driving plate (fij with a high-melting-point grease. Slide section of the driving plate into the slidit of the clutch assembly.mogels VU-1U,"UuU ana II Section NI. INSTALLATION 46. PRIOR TO INSTALLATION. ENGINE ALIGNMENT TESTS The ongine must be checked for trueness of the flywheel and the jivwheel hous: ing. Thoroughly clean ihe engine {ly wheel and flwheel housing prior to the making of the following oh is. Be sure ran the engine cra earl to ie ald end pias inh ‘ AL Checking Face of Ersian Flywheel Nouw jing. Bolt a thousandths (dial indicator) gauge to the engine flywheel so that the indicator is perpen- dicular to the face of the engine flywheel housing, and the indicator stem is riding on the face of the flange (fig. 42). Rotate the engine flywheel and ENGINE FLYWHEEL HOUSING ENGINE FLYWHEEL Figure 42. Checking Engine Flywheel Housing Face. note the face deviation of the engine flywi ing flange. The face deviation must 0.008" ENGINE FLYWHEEL HOUSING + ENGINE FLYWHEEL Figure 43. Checking the Bore Concentric Flywheel Housing. B. Checking Bore of Engine Flywh ing. With the indicator attached as in adjust the indicator stem so that it will r bore face of the engine flywheel housing Rotate the engine flywheel and note the centticity must not exceed 0.008". C. Checking the Clutch Cover Moun Attach a dial indicator to the engine flyw! ing so that the indicator stem is just on t the cap sctew holes in the flywheel fac mounting the clutch cover. Rotate the and note the runout variation, Runout must not exceed 0.008" total indicator swinT t ter myarauliic 1orque Converter ‘cLurc cover PLATE SURFACE DRIVING PLATE ASSEMBLY SURFACE ENGINE FLYWHEEL |GINE FLY WHEEL HOUSING iN IEEL HOUSINt Figure 44. Checking the Clutch Cover Mounting Surface Runout. D. Checking the Clutch Driving Plate Sur- face. Attach the dial indicator to the flywheel housing so that the stem of the indicator is perpen- dicular to the machined face on the flywheel for the clutch driving plate. Rotate the flywheel and note the variation in runout. The maximum permitted run- out is 0.0035" total dial indicator travel. Us encine ruywneet u DRIVING PLATE ASSEMBLY SURFACE ENGINE FLY WHEEL iS Figure 45. Checking the Clutch Driving A Plate Surface of the Flywheel. 47. INSTALLATION. A. General. The alignment of th converter with the engine is an extremely : factor in obtaining lengthy, troublefree sen, formance from the torque converter. An e minutes time spent for an accurate and pt stallation will be returned many times in unnecessary future downtime. B. Attachment. Install two guide p 16 x3 into the flywheel threaded holes for th assembly cover plate and set the complet assembly in place on the flywheel over t!moaels VU-1U,UUU and II pins. Align the driving plate and pressure plate as- sembly to the flywheel center. Install ten 3/8-16 x 1-1/2 hex-head cap screws to the flywheel and evenly tighten four, 180° from each other. Remove the guide pins and install the two remaining cap screws. Tighten all the cap screws evenly to 38 Ibs.-ft. torque. Attach a dial indicator to the engine block so that the stem contacts the flywheel hous- ing. Adjust the indicator, so the stem can travel downward, and zero the dial. Install two 6-inch guide pins in the flywheel housing to align the clutch housing. Attach suitable lifting hoist equipment to the converter assembly. Raise the unit and level it with the engine assembly. Move the converter as- sembly toward the flywheel, indexing the input shaft splines through the clutch sliding sieeve and collar into the driving plate. Turn the flywheel slightly to engage splines. At the same time the sliding sleeve must be indexed with the sleeve carrier and the operating fork must be engaged over the shifter blocks. Also, the lubrication hose from the sliding sleeve must be dressed toward the fitting in the clutch housing. These operations can be assisted by working through the cover plate opening in the clutch housing. Attach the lubrication hose (fig. 67, 17) to the fitting (20) in the clutch housing. When the clutch housing mating face is squarely located against the flywheel housing, install the cap screws or studs with nuts and secure the clutch housing to the flywheel housing. Remove guide pins. Adjust the clutch and lock the adjusting ring (paragraph 7). C. Alignment. Attach the rear mounting plate to the output housing and mount the rear hous- ing to the machine, Note the deflection from zero on thedial indicator previously attached as the con- verter assembly is lowered into final mounting attitude. Add shims as required at the rear mounting plate to align the engine and converter assembly. The shims should result in returning the dial indi- cator to zero. D. Miscellaneous. Complete the installa- tion. Connect cooler lines, controls, governor cable, etc. E. Air Leakage Test. The following torque converter air leakage test should be performed to determine if assembly of the converter was made correctly with no leaks present. (1) Making the Converter Air Tight Disconnect the orifice filter vent line from the top of the fluid cooler and install a plug in its place. Disconnect the fluid pressure gauge flexible hose at the pressure gauge and at the “tee” fitt the fluid filter. Braze an inner tube (Shr: valve to a 1/8-inch pipe nipple and install nipple in the reducing “tee” fitting. (2) Connecting Test Air Gav move the 1/2-inch socket head pipe drain the bottom of the turbine housing. Instal psi air pressure gauge in this 1/2-inch pi hole. (3) Testing for Leaks. Ch converter with 30 psi air pressure. CAUTION Donot use more than 30 psi air press The fluid seal assemblies in the to: converter may be damaged as a re of excessive air pressure, Inspect all fittings, connections and lin fluid system circuit for leaks. Squirt a sma of converter fluid with a small oil can a ateas suspected of leakage. Look for air denoting a leak. Note air pressure gauge pressure is held steady, or dropping off i leakage. Disconnect the front and rear s hose and tube. Inspect the tube and hose ait leakage. A leak from these seal drain an indication of a leaking fluid seal. I volume of air is leaking from a seal dr manually rotate the input and output shafts. This action may seat the fluid se: blies. If severe leakage persists, the to verter will have to be disassembled and to determine the cause of leakage: (4) After Test. Finalize the tion. Remove all test equipment and re connections, etc. Connect drive line to out, Install the cover plate gasket (jig. 66, 17) (78). Secure the plate and gasket to the with four hex-head cap screws (20) 3/8 and lock washers (19). Tighten the scre Ibs. ft. torque. 48. AFTER INSTALLATION, A. Lubrication. Fill the tubricati bers with lubricating oil (paragraph 22C). B. Fluid System. Fill the fluid sy: fluid (paragraph 22D).Hydraulic lorque Converter C. Clutch Adjusiment. Refer to paragraph 7D. 50. RECOMMENDED AND APPROVED Gi Section XI. RECOMMENDED FLUIDS ‘The Table IV contains a non-exclusive list ¢ OILS AND GREASES mended ball and roller bearing greases suitable for use in hydraulic torque converte 49. RECOMMENDED AND APPROVED CONVER- 51. RECOMMENDED AND APPROVED TER FLUIDS. CATION OILS. The Table Ill contains a non-exclusive list of recom- ‘The Table V contains a non-exclusive list ¢ mended fluids that have been tested and approved mended lubricating oils which have bee by Twin Disc. Incorporated for use in hydraulic and approved by Twin Disc, Incorporated fo: torque converters torque converters. See paragraph 23. Table Ill, Recommended and Approved Converter Fluids * THREE STAGE CONVERTER FLUID It has been called to our attention that three stage converter fluid is not as readily available as it once was. Some oil companies have withdrawn their formerly available products. If you are unable to obtain a suitable fluid from local oil company sources, we suggest you contact your nearest Twin Disc Distributor. Many of our distributors are stocking this fluid and offer it in convenient sizes (5 gal., 10 gal., etc.). Fluid is also available from your Twin Disc Distributor in 55 gallon drums. Twin Disc’s part number for a 55 gallon drum is M201653. The drum furnished is non-returnable, the shipping weight is 415 Ibs. and there are no special restrictions which apply to shipment of drums of fluid. Check with your local Twin Disc Distributor for the current drum price. Below is a partial list of manufacturers who have recently advised that they offer our fluid. PRODUCT NAME MANUFACTURER RPM Torque Fluid No. 2 Standard Oil Co. {Calif.) BURMAH Torque Fluid No. 2 Burmah Oil and Gas (Los Angeles) CONOCO Twin Disc Torque Fluid Continental Oil Co. (Oklahoma) SKELLY Torque Converter Fluid Skelly Oil Co. (Oklahoma) DONAX T1 Shell Oil Co. ANTAR CC-3 Antarpetroles De L’Alantique (Europe only) BP Energol Hydraulic Fluid Twin Disc British Petroleum Co. Ltd. (Canada & Europe only) * Where diesel fuel is used, a quality minimum corrosive type is recommended.Table IV moaeis CY-1U,UUU and II Recommended Greases for Hydraulic Torque Converters. Trade Name Shell Darina AX or Retinax A Gulflex A Super Permalube Grease Mobilgrease MP or Mobilux Grease No. 2 RPM Automotive Grease, Med. Lithoine MP Unoba Philube 1B & RB Norma 66 1990 Multifak 2 Prestige 42 Grease Trojan H-2 Keystone No. 89M No. 646 DX All Purpose Grease Veedol All Purpose Grease Kenlube L-421 BP En Ergrease L2 Enco Multipurpose Grease Castrolease LM or Spheerol Apt. 2 Manufacturer | Shell Oi1 Company Gulf Oil Corporation American Oil Company Socony Mobil Oil Company Standard Oil Company (Calsfornia) Sinclair Refining Company Union Oil Company of California Phillips Petroleum Company Norma Hoffman Bearing Company Texaco, Inc. Sun Oil Company Cities Service Oil Company Keystone Lubricating Company DX Sunray Oil Company Tidewater Oil Company Kendall Refining Company British Petroleum Company Limited Humble Oil & Refining Company Castrol Limited (England) Table V. Approved Oils for Hydraulic Torque Converters. Trade Name Manufacturer Rotella Mobiloil American HD-M Havoline Motor Oil TSX or Unite DX Motor Oi Rubilene Super HD or Super Tenol C300 Series BP Energol Diesel D Phillips 66 Super RPM Delo Special Dual Action HD-1 or Kendall F-L Veedol High Detergency Sunoco Ocnus Mil. or Supplement 1 Gulf Dieselube HD Deusol Cr. (Proper Viscosity) Conoco Super Motor Oil Encolube H DX Shell Oil Company Socony Mobil Oil Company American Oil Company Texaco, Inc. Union Oi Company of Califomia DX Sunray Oil Company Sinclair Refining Company Cities Service Oil Company British Petroleum Company Limited Phillips Petroleum Company Standard Oil Company (California) Kendall Refining Company Tidewater Oil Company Sun Oil Company Gulf Oil Corporation Castrol Limited (England) Continental Oil Company Humble Oil & Refining Companymyarauic 1orque Vonverrer Section XII, safer. Twin Disc, Incorporated will not mar SPECIAL TOOLS these tools for general use. Section XIV. PARTS LIST 52, SPECIAL TOOLS. 53. GENERAL. Figures 46 through 65 in this section identify the special tools by tool number. All pertinent informa- Use figures 66 through 72 and the adjacei tion necessary for the fabrication of these tools in lists for ordering spare or replacement part: the field is shown on each tool drawing. These cordance with the instructions contained i tools will make overhaul procedures easier and graphs 3 and 4. me, ye wowor-/ 413/84] DESCRIPTION STOCK SIZE PLUG 4 DIA «24/1 TUBING 3.500 1 40.0. x5, Key 3/8 x 3/8 x1. M-Z2B1 BEARING LOCK NUT BAR 1 DIA. «12 Figure 46. Special Tool T-11896.moagels CY-1U,UUYU anda II, Pio p.IN TUBE | TUBING 1-3/4 LD. 21/400. Figure 47. Special Tool T-11899,myaraulic torque Converter DET.| REQ. | MAT. 1 1 1moaen Vy-1u,;yuY ang 1 sv KNuRL 6S Figure 49. Special Tool T-11913.nyarauic 1orque Vonverrer 11/2 HEX 1/4-20 THREAD: 12-13 THREAD: 1-1/2 HEX. rr DIA. aie WELD 360% 3/4 3/8 DIA. ' 43/48 * 4 | Luxe 7706 11/2 DIA. Wa 1-976 DIA. 5/8 DIA. SS aya 1/2413 TAP 9/6 DIA. (8) 5/16 DIA. BALLS NORMA-HOFFMANN HW-9/16 OR EQUIVALENT Figure 50. Special Tool T-11912.MVUUsIs VY-1U,VUU ang It STEEL PLATE wero 360° | Wa Figure 51. Special Tool T-11914. 10.1/2 COARSE KNURL 3/32 x15* CHAME. ‘MATERIAL: 1020-CARB. & HARDEN, Figure 52. Special Tool T-202315.nyarauic 1orque Converter 7/16 1/2 1/8R. 3/16 DIA. 3/16 SPRING ST. TREQ'D 1/2 E.M.T. Figure 53. Special Tool T-206769. 3.7/8. BORE———> |-— 3.000 v1, aml A a] tal iif : 20 —| Figure 54. Special Tool T-11897.moagers CYU-1U,VUU ana I MQ ® N.GH*SL- B3AII0 s Resim vet swr-onta ® 4 seas arnyarauiic 1rorque VConverter 4DIA. v2 WELD 360° DET.[ REQ. |MAT. | _ DESCRIPTION STOCK SIZE 1] [us] puate 4DIA. x 172 2 [a |e | ruse-so0. 3.1/2 1.0. x 4/8 3 [a [us | puate-61200] 31/410.21/72 Figure 56. Special Tool T-11901.moageis VY-1u,yvuyU and II ge Tei BASE |, ____ 5.1/2 pia ___| 744k nee 20 —| Figure 57. Special Tool T-11898.Wei ize | COeey-sant | a] 1 |e ia wer Biviaona | swi t | 1 wa Bzis 01s | NoWanussaa_| vw | -oau| 13a +096 alam. ose Myaraulic torque ConverterModels CU- 10,000 and | WELD 3602 Z SSSSSSSSSE SES CASE HON. THIS END, Figure 59. Special Too! T-11903. 1778 L{ |sayao 2 4 a fet f ol = Figure 60. Special Tool T-200448.E> Hydraulic lorque Converter HIS POINT TO BE FI (OF SOLDER TO HOLD LOOP'"# NOTE RADIUS GIVEN AS GUIDE ONLY, TO FACILITATE HOLDING ROLLERS IN ASSEMBLY Loop "a" WIRE WRAP 1/6 \\ XX afer ie ye ESTIMATED STRAIGHT teNoTH 14:72 ‘#18 GAUGE (.040) BRIGHT SPRING STEEL WIRE #20032 cave Jon non wint Loop van \_ ASSEMBLED position tor “a 3/ 2. wike Twist 20-3/4 Figure 61. Special Tool T-11925.Models VU-1U,UUU and | An = : ma af a9 pe pa tavaoin wees Hag vad on AME 39 Figure 62. Special Too! T-203713. (Cro ee [Roo rao rans Tawa [vase ae V2, 3 B” Ne Oe ‘MED. KNURL “Fea x “a” DIA ———— Ret f f tt “D" DIA. “C”DIA. O.H.T.S. HDN. R.C. 48-52 Figure 63. Special Tool T-209975.Hydraulic lorque Converter WELD 360° WELD 360% 4-7/6 DIA. 415/160 + 9.ya pet. | REQ. |MAT.| DESCRIPTION STOCK SIZE 1 [1 [ws | Puate V/A DIA. «3/4 2 [1 | | tupe-soo. 49/810. «8.178 3 [1 [ms | ptate 5 DIA. x1/2 bo Figure 64. Special Tool T-11907.moagels LY-1U,uvUYU and I 8/2 “t 3-15/32 DIA. WELD 360° Figure 65. Special Tool T-11915moaeis LU- INPUT GROUP. u,vuy ana il Description Quantity CARRIER, sleeve, sliding GASKET, seal assembly SEAL, oil SHAFT, input WASHER, lock, spring 3/8 SCREW, cap, nexhead 3/8-16 x 1-1/4 BEARING, bail RING, snap, external RING, £0” FORK, throwout WASHER, key 5/16 WASHER, lock, spring 1/2 SCREW, cap, hex-head 1/2-13 x2 GROMMET, housing, clutch HOUSING, clutch SAE No. 1 BOLT, eve GASKET, plate, cover PLATE, cover WASHER, lock, spring 3/8 SCREW, cap, hex-head 3/8-16 x 3/4 PLATE, name and instruction SCREW, drive PLATE, engine oil SCREW, drive GROMMET, housing, clutch FITTING, grease GROMMET, housing, clutch NUT, 5/8-11 GROMMET, housing, clutch STUD, 3/8-2 5/16 CAP, pipe 1/2 NIPPLE, pipe 1/2 x 3-1/4 WASHER, lock, spring 3/8 NUT, regular 3/8~24 GASKET, pump opening PLATE, hole, hand SCREW, button head 1/4-20 x 1/4 SEAL, dust BEARING, needle SEAL, dust SHAFT, operating SEAL, dust BEARING, needle SEAL, dustHydraulic torque Converter Figure 67. Clutch Group of Parts.moaels LU-1U,UUU and II CLUTCH GROUP hte Description Quanti'y 1 PLATE, driving, assembly 2 BEARING, needie, closed end 3 PLATE, pressure 4 PIN, lever 5 ROLLPIN 6 LEVER, pressure plate assembly © LEVER, pressure plate b ROLLPIN © COLLAR 4 LINK ¢ PIN, headed 7 RING, adjusting 8 PLATE, clutch cover assembly © PLATE, clutch cover b SCREW, hex-head cap 3/8-16 x1 € LOCK, adjusting ring 4 ROLLPIN 9 ROLLPIN 10 COLLAR 11 COLLAR, release bearing 12 SLEEVE, sliding 13 BEARING, ball 14 RING, snap 15 RING, snap 16 FITTING, elbow 1/8 x 45° 17 HOSE, flexible 18 PIN, cotter 19 BLOCK, shifter 20 FITTING, hose 1/8 21 WASHER, lock shakeproof 22 NUT, jam 23 PIN, headed 24. SPRING, releaseModels CO-10,000 and 11, END PLATE GROUP OF PARTS Item Description Quantity SCREW, set, locknut 1/4-20 x 5/8 NUT, lock, bearing 12NS-3 thd. WASHER, lock, bearing SPROCKET, chain KEY, sprocket, chain 3/8 x 1/4 x 5/8 CHAIN, roller 3/8-ineh BEARING, ball, split, impeller SEAL, oil shaft GAUGE, oil level 10 NIPPLE, breather and oil level gauge 11 PLATE, end 12 GASKET, ring 13 SCREW, hex-head cap 3/8-16 x 1-1/4 14 WASHER, lock 15 HOUSING, sprocket 16 GASKET, sprocket housing 17 PIN, dowel 18 BALL BEARING, auxiliary pump shaft 19 SPROCKET, chain 20 KEY, Whitney 21 SHAFT, auxiliary pump 22 BALL BEARING, auxiliary pump shaft 23 RING, snap, intemal 24 GASKET, fluid pump 25 PUMP, assembly 26 SCREW, hex-head cap 27 WASHER 28 GASKET, seal 29 SEAL, fluid, assembly 30 SCREW, cep, twelve point 3/8-16 x 1 31 RING, mating, carbon 32 WASHER, ring, mating 33 IMPELLER WHEEL 34 KIT, service seal assemblyModels CO-10,000 and BASIC GROUP OF PARTS Ite Deseripin Quantity 1 RING, snap, extemal i 2 ROLLER BEARING, freewheel 1 1 4 3 CAM. freewheel 4 ROLLER, freewheel ¥ 5 CAGE, assembly 1 ® CAGE, freewheel roller tt b ROLLPIN, cage spring 2 6 SPRING, bumper 5 7 WASHER, bearing lock 1 8 NUT, bearing lock 1 9 SCREW, set 1 10. SPRING, cage return 2 11 TURBINE WHEEL ASSEMBLY 1 12 WASHER, mating ring 1 13. RING, carbon mating 1 14 FLUID SEAL ASSEMBLY 1 0 NOSE PIECE, fluid seal 1 b SPRING, compression 8 © WASHER, spring retaining 1 4 SPRING, garter 1 e ELEMENT, rubber 1 ¥ CARRIER, fluid seal di 9 SEAL, shaft 1 h CLIP 2 k SCREW, round head cap 1/4 x 1/2 2 15 GASKET, seal assembly. 1 16 SCREW, twelve point cap 6 17 VALVE, angle drain 1/4-inch 1 18 SCREW, hex-head cap za 19. WASHER, copper 2 20 HOUSING, assembly, turbine 1 21 GASKET, bearing retainer 1 22 BALL BEARING, double-row, turbine 1 23 WASHER, bearing lock nut 2 24 NUT, beating lock 2 25 SCREW, set, bearing lock nut 5/16-18 x 3/4 1 26 PLUG, drain 1/2-inch 1 a |. o = = o > c ° Vv o > ov = ° e 2 SI 3S = zo ~ =xModels CO-10,000 and 11 OUTPUT GROUP Description Quantity SHAFT, output KEY, 3/4 «3/4 x4 RETAINER, bearing SCREW, 12 point 3/8-16 x 3/ RING, snap, internal BEARING, roller, spherical SEAL, oil GAUGE, oil level NIPPLE, breather BOLT, eve PLATE, lubricating oil SCREW, drive STUD, 3/8 x 1-1/4 WASHER, lock spring 3/8 NUT, regular, 3/8 HOUSING, output bearing and spiral gear PLUG, pipe 1/8 PLUG, pipe 1/2 NUT, jam 5/8-18 WASHER, plain 5/8, GASKET, ring FITTING, hose HOSE. flexible ELBOW, street RING, gasket SPACER, tubing (converter) GEAR, spiral KEY, Woodruff SPACER, gear ADAPTER, flexible casing BEARING, plain SHAFT, gear BEARING, flange PLUG, expansion PLUG, pipe 1/8 SCREW, setHydraulic Torque Converter Figure 71. Fluid Group of Parts.Models CO-10,000 and 11, FLUID GROUP Ite» Description Quantity GAUGE, fluid NUT, regular 3/8-24 WASHER, lock, spring 3/8 FILTER, assembly KIT, service, filter, fluid © ELEMENT, filter, fluid b GASKET, filter, fluid 6 BRACKET 7 PLATE, instruction 8 SCREW, drive 9. SCREW, cap, hex-head 3/8-16 x 3/4 10 WASHER, lock, spring 3/8 11 SHIELD, heat 12 MOUNTING, gauge 13. SCREW, cap, hex-head 3/8-24 x 3/4 14 WASHER, lock, spring 3/8 15. SCREW, cap, hex-head 3/8-16 x 3/4 16 7 8 y 20 GAUGE, temperature GAUGE, pressure SCREW, drive PLATE, converter fluid NUT, regular hex 3/8-24 21 WASHER, lock spring 22 PLATE, cover 23 GASKET, reserve tank 24 FILTER, screen 25 TUBING, stand pipe 26 FITTING, connector, male, inverted 1/4 27 WASHER, lock, spring 3/8 28 SCREW, cap, hex-head 3/8-16 x 3/4 29: TANK, reserve 30 PLUG, pipe, squarehead 1/4 31 NIPPLE, pipe close 1/4 32. FITTING, elbow, male, inverted 1/4 33 FILTER, orifice, assembly « HEAD, orifice, filter b GASKET, asbestos copper ¢ ELEMENT, filter orifice 4 BODY, orifice 34 FITTING, connector, male, inverted 1/4 35 TUBING, stand pipe 36 GASKET, pipe flange 37 FLANGE, pipe 38 WASHER, lock 39 SCREW, hex-head cap 3/816 x 1-1/4Hydraulic Torque Converter Figure 72. Fluid System Parts.Models CO- 10,000 and 11 FLUID SYSTEM PARTS tem Description Quantity 1 FITTING, connector 2 TUBE, pump+to-filter 3 TUBE, filter-to-end plate 4 FITTING, elbow 5 FITTING, elbow 6 7 8 9 ELBOW, pipe HOSE FITTING, elbow TEE, pipe, reducing 10 BUSHING, reducer 11 ELBOW, street 12 HOSE 13 ELBOW, street 14 ELBOW, front seal drain 15 TUBE, end plate-to-reserve tank 16 TUBE, pump-to-reserve tankIDENTIFICATION OF INLET AND OUTLET PORT FOR STANDARD CONVERTER CHARGING PUMPS ‘The general rule for determining the inlet and outlet side and proper direction of rotation for these pumps is given below. 1. Inlet or suction port is always on the same side of the pump as the relief valve. 2. When viewing the pump from the shaft end with the relief valve cap on the horizontal center line the top of the pump shaft (and pulley) must rotate in the direction of the outlet port. Shaft Side Outlet Port Va Inlet poft on inlet this side. : this Right Hand Pump Left Hand Pump {tis very important that these pumps be driven in the correct direction. Rotation in the ‘opposite direction will not permit the relief valve to function and will therefore cause excessive pressures in the converter charging system.TORQUE ror richtenine capscrews, BOLTS, NUTS, VALUES tee rirtines ano piucs. CAP SCREWS, BOLTS & NUTS: TAPERED PIPE PLL TORQUE (Le, FT.) FOR COURSE AND FINE THREADS (| [RECOMMENDED TOROUE | ania womat | sae GRADES sae raves | Util wre Lusricar THREAD ton opt DIAMETER as (2il cusni-(3/ as (2) Lusrt-iai] LuBRE (3) Incastiron | 4, RECEIVED CATED RECEIVED | CATED CATED or Stee! Wa m | sei | vec] wea] ne) inea7 | astio 5/16 1922 15+ 2 2| 22% 2 8-27 10.5 +13 3/8 3323 2+ 2 46+ 4] 38+ 3 14-18 t3 16 6224 ans 73+ 6| 60+ 5} 64+ 4 3/8-18- 743 V2 80:6 Gt 5 112+ 8] 904 7} 100 W214 50+ 6 ans | uizes | se > | ts8+12| 1308 10] ---- wars | gat > 5/8 158 +12 130 #10 224+ 16] 180% 15) 190210 1 -111/2} 80410 34 280 +20 225 £20 390+ 20} 3204 25] 330217 114-111/2] 85410 18 448 432 360 +30 630+ 50| 510+ 40) 510+25 112-11 1/2] _85+10 1 680 250 | 540 245 960+ 70| 775 + 60] . 11/8 850 +60 | 675260 | 1360 100 |1100+ 25) . (a) THE LUBRICANT IS TO 1a [rr7s ses _| 925275 | ras0 #150 [rg00 #125 SANE INSOLUBLE PLAN 3 basnes 6 pasnes AND PLuGS Ane TO SecA abapant corapant om Removal wiTaourt T RiTiAL Kearage fue ewoVat atone AN oF! co B REMOVAL CONDITIONS ARE saesranoano ex soureaowannines | 12% yous aoe ‘ay (1) THESE TORQUE VALUES APPLY TO USE OF IRONS, STEELS AND ALUMINUM TAPPED HOLES. THE THREAD ENGAGEMENT LENGTH ALUMINUM IS TO BE TWICE THE NOMINAL THREAD DIAMETER AND ENGAGEMENT LENGTI BE | SFORIRONS AND SOFT STEEL WHEN ZINC PLATING IS USED. LUGAICATE THE ZINC PLATED SURFACES OF THE SCHEWS ANDI ¢ USE SPECIAL TOROUE VALUES. (2) USE FOR ALL CAPSCREWS, BOLTS AND NUTS COATED ONLY WITH THE FASTENER MANUFACTURE PREVENTATIVE Olt AND USE FO PARTS WIPED OR WASHED NEARLY FREE OF OIL. DO NOT USE FOR PLATED. (3) USE FOR ALL CAPSCREWS AND NUTS WHOSE THREADS AND WASHER FACE ARE LUBRICATED. ALSO FOR S NUTS WHOSE WASHER FACE IS ASSEMBLED AGAINST A HARDENED WASHER OR SMOOTH FINISHED HARO P, OR ABOVE AND 40AA MAX). ALSO USE FOR PLATED SCREWS (EXCEPT ZINC PLATED). LUBRICATING THE THR SCREW OR NUT FACE WITH SAE 20 OR 30 OIL IS RECOMMENDED FOR BEST RESULTS FOR ALL THE GRADE &SC IS REQUIRED FOR ALL THE UNIVERSAL JOINT BEARING CAPSCREWS. DO _NOT USE MOLY.DISULFIDE, WHITE LEAD, COPPER FILLED OR OTHER SUCH FILLED LUBRICANTS Wi ‘TORQUE VALUES, SUCH LUBRICANTS REQUIRE’ SPECIAL TORQUE VALUES, ® SOCKET HEAD SCREWS AND 12 POINT HEAD SCREWS WITH FULL BODY ARE GRADE 8 OR BETTER QUALITY Al BE ASSEMALEO WITH THE ABOVE TORGUE VALUES,BEARING LOCKNUT TORQUE 0 ny i ee ee ee eee | wre | sent 01 Bc Bt 2 oe A Me 5 4 8 46+ 6 05 c c 75 10 06 Do 92+ 12 7 E 125+ 16 E 150 08 F F 180+ 20 AF 230 30 (a) F 190 03 6 GS 200+ 25 (2) AG 300 + 40 6 240 10 H 4 240 = 30 AH 370 + 50 H 290 u J 1 290 + 49 Al 440 + 55 J 350 2 kK k 350 + 45, AK 530+ 70 K 430 3 b 400+ 50 AL 800 + 75 L 490 4 M M 460+ 60 | AM 710 + 90 ™ 580 1 N Al 550 70 AN 830110 |} N&AN 680 16 P E 880+ g5 AP 1000 +130 P 800 "7 a 770 * 100 AQ 1200 #150 a 960 18 - 900 + 120 AR 1350 #170 R 1100 13 s S&AH | 1000 + 130 AS 1500 £190 8 1300 20 T 1180 + 150 AT 1700 #225 T 1400 a u 1300 + 170 AU 2000 +250, u 1600 2 v v 1400 + 180 AV 2200 +275 v 1800 a w 1800 + 225 AW. 2700 +250 w 2200 6 x x 2200 + 275 AX 3300 +425 “ 2700 28 Y 2600 + 325 ay 4000 +500 Y 3300 30 Zz 3100 # 400 AZ 4800 +600 z 4000 o a TORQUE VALUES APPLY TO SOLID SHAFTS. ‘TORQUE VALUES MAY OR MAY NOT BE SATISFACTORY ON THIN-WALLED SHAFTS, TORQUE VALUES APPLY TO THREADS LUBRICATED WITH SAE 20 OR 20 OL, 1M-2281.AG IS TO HAVE SAME ASSEMBLY TORQUE AS M.2012.86. 1M.2037.AA IS TO HAVE 120 £16 LB. FT. ASSEMBLY TORQUE.STRAIGHT THREADED TUBE FITTINGS, HOSE FITTINGS AND PLUGS WITH “O" RINGS. FOR 377, 45° AND INVERTED FLARED FITTINGS PER SAE STANDARDS J512, J614, and J516 WITH LATEST SUFFIX. FOR TAPER PIPE THREADED FITTINGS USE THE PIPE PLUG TORQUE VALUES SHOWN ON PAGE 1. a NomINAL | NOMINAL TIGHTENING uHaUE THREAD TUBE TORQUE,LB.FT. | 9 WN cant. 0.0. SIZE NUTS & PLUGS ‘ 5/16 3/8 16 2 9/16 & 5/8 1/6 34 118 vane 13/16 & 1-1/4 15/16 & 1-3/8 15/8 1-718 2412 (1VTHIS CHART DOES NOT APPLY TO OTHER THAN THE 2 FLARED DESIGNS QUOTED. THUS DO NOT USE THIS DATA FOR SLEEVED COMPRESSION TYPE FITTINGS, REFRIGERATION TUBE FITTINGS, AIR LINE TUSE FITTINGS NOR THE MANY FLARELESS FITTINGS. (2) THIS IS A PARTIAL LIST. USE THREAD 0.0, TO DETERMINE THE RECOMMENDED ING PLUGS, [ASSEMBLY TORQUE OF THE UNLISTED STRAIGHT THREAD “ ‘THE FLARELESS FITTINGS ARE BEST ASSEMBLED WITH NUMBER OF TURNS AFTER SOME INITIAL TIGHTENING OR RUNNING TO THE STOP PROVIDED AND THEN TIGHTENING WITH AN ADDITIONAL § TO 50 POUNDS FEET OF TORQUE. NO STANDARD DATA HAS BEEN PREPARED FOR THE FLARELESS FITTINGS.GENERAL TWIN DISC WARRANTY A. Twin Dise, Incorporated guarantees all assembled products and parts, (except component products or parts on which written warranties issued by the respective manufacturers thereof are furnished to the original purchaser, as to which Twin Disc assumes no liability) against defective materials, or workmanship for a period of eighteen (18) months from the date of original shipment by Twin Vise to its customer, but not to exceed twelve (12) months or two ‘thousand (2,000) hours of service, whichever occurs first. The original purchaser does not rely upon any tests or inspections to such products or parts by Twin Disc. No other warranties express or implied are intended or given by Twin Disc, Incorporated ‘The exclusive remedy provided by Twin Disc, Incorporated within the applicable warranty period specified in paragraph “A” shall be, at the sole option of Twin Disc, either the repair or replacement of any part or product found by Twin Disc to be defective, or a credit for any such part or product. subject to the following terms and conditions: 1. Complete parts or products must be returned to Twin Disc, Incorporated within the warranty period, transportation charges prepaid. 2. This warranty is void if, in the opinion of Twin Disc, Incorporated the failure of the returned part or product resulted from abuse or neglect or where such failure has been caused by accident. 3. Labor or other costs or expenses incurred by the buyer for removal, reinstallation and repair of the Twin Disc part or product is not covered by this warranty and the buyer assumes full responsibility for such costs and charges. 4. The warranty is void unless the buyer or his agents provides proper transportation and storage facilities and reasonable care of the complete product or part from the date of shipment to the date placed in service. 8. This warranty is void unless the buyer causes the product or part to be properly installed. within the rated capacity of the product or part with installations properly engineered ‘and in accordance with the practices, methads and instructions approved by Twin Disc, Incorporated. 6. This warranty is valid only if all required replacement parts or products are of Twin Dise origin or equal, and otherwise identical with components of the original equipment. 7. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc, Incorporated, C. In consideration for this warranty buyer agrees to indemnify and hold seller harmless from and against all and any loss, liability, damages or expenses for injury to persons or property, including, without limitation, buyer's employees and property due to the acts or omissions of the buyer, its agents, and employees in the installation, use and operation of said equipment and shall assert no claim against seller for consequential damages, D. Only authorized factory representatives of Twin Disc, Incorporated shall have authority to assume any cost or expense in the service, repair or replacement of any part or product within the warranty period except when such cost or expense is authorized in advance in writing by ‘Twin Disc, Incorporated, E, Twin Disc, Incorporated reserves the right to improve the product through changes in design or material without being obligated to incorporate such changes in products of prior ‘manufacture. Buyer will not rely on any such changes as proof of insufficiency or inadequacy of prior designs or material. naMost Twit Dise products are made to be mounted directly on the flywheel of the cugine. 11 is possible, due tw mismatch of components or many other reasons, 10 have flywheel to driven component interference. As a result, it is necessary that engine crankshaft end play be measured befure the driven component is installed, After installation of the driven component, crankshaft end play: should uguin be measured. The second measurement should be the same us the Jirst end play measurement If it is not the same, it could be an indication of interference. Consequently, the driven component should be removed, the source of interference found and corrected, Twin Dise will wot be responsible for arstem dainage caused by engine to Twin Dise component interference regardless of she cause of interference, This engine crankshaft end play: cheek is considered mandatory. LIFTING EYEBOLTS Twin Dise can supply lifting eyebolts for most of its products. They range in size from (3/8) thread to (1-1/4) thread and ultimate to: capacity of (3) ton to (33) ton. Consult the Service Engineering Department 1328 Racine Street, Ri 53403 U.S.A. cine, WisconsinAPPENDIX | OUTPUT GROUP OF PARTS WITH CHAIN-DRIVEN GOVERNOR DRIVEHydraulic Torque Converter APPENDIX | OUTPUT GROUP OF PARTS WITH CHAIN-DRIVEN GOVERNOR DRIVE GENERAL INFORMATION Section I. 1. DESCRIPTION. A. General. A new govemor take-off drive was incorporated in output housings for three-stage torque converters in May 1965. This governor take- off drive is a chain and sprocket type design. Changes required to adapt the former output group of parts to the new design involve the output housing and the oil level gauge and tube. Additional parts for the new group include the sprocket housing, sprockets, chain, idler shaft assembly, bearings, governor drive adapter, and cover plate. B. Output Housing. The new output housing provides an opening on the top rear section for mounting the sprocket housing. Shims are used be- tween the sprocket and output housings to adjust chain tension. The output housing also contains provisions for the installation of a separate oil level gauge and a breather cap. In all other respects, the housing is very similar to the former output housing. C. Sprocket Housing. ‘The sprocket housing is mounted to the top rear section of the output housing. Shims are used between the sprocket and output housings to adjust chain tension. The sprock- et housing contains the idler shaft assembly, the driven sprocket, and two ball bearings. A cover plate is mounted on the top of the: sprocket housing with a gasket and two cap screws. Removal of the cover plate provides access for chain inspection and/or removal. The sprocket housing also has a mounting surface for the governor drive adapter. A 1/4-inch pipe plug hole is provided in the sprocket housing for removal of the idler shaft. Normally, a pipe plug is installed in this hole; however, a friction- type test tachometer can be installed in’ the tapped hole, if desired. D. idler Shaft Assembly. The idler shaft as- sembly consists of the idler shaft and the idler shaft sleeve. The idler shaft is mounted between two ball bearings that are installed in bearing bores of the sprocket housing. The protruding end of the idler shaft is slotted to accomodate the flexible cable for the governor drive. The idler shaft sleeve is installed ‘on this end of the shaft and in the govemor drive adapter. E. Driven Sprocket. The driven contains eighteen teeth and is keyed on : shaft The hub section of the sprocket is i to the rear of the sprocket housing. F. Driving Sprocket. ‘The driving contains forty-four teeth and is keyed on th shaft. The driving sprocket spacer loc: sprocket 1 the shaft with the hub sectio sprocket snstalled to the rear of the output G. oller Chain. The single-stran chain with 3/8-inch pitch is used to tran drive from he output shaft to the idler sh chain contasns a master link for installatior moval. Access to the chain for installation moval is made through the cover plate op: the top of the sprocket housing. The chait be adjusted for minimum slack without ter the addition or removal of shims between the : and output housings, 2, PRINCIPLES OF OPERATION. A. General. The output shaft dri keyed driving sprocket. The driving sprocke fers the drive to the driven sprocket thro roller chain. The keyed driven sprocket ti idler shaft. The flexible cable to the gov connected to the idler shaft and turns with tl at shaft speed. B. Governor Drive Speed. The driving et has forty-four teeth and the driven sproc eighteen teeth. Therefore, the governor ¢ driven 2.44 times faster than the output shafi 3. LUBRICATION. A. Oil Supply. The oil for lubricatio govemor drive group of parts is contained Sump at the bottom of the output housing. B. Lubrication. Part of the driving s and chain are immersed in the oil within tht ‘Therefore, all parts within the sprocket hous lubricated by the oil on the chain as the chai ‘on the sprockets.Output Section I. PREVENTIVE MAINTENANCE 4. GENERAL. ‘The same procedures for preventive maintenance as described in the main sections of this manual apply to the output group of parts with chain-driven gover- nor drive. In addition, the following cleaning and inspection procedures should be accomplished. 5. CLEANING. Clean the chain and sprockets with an approved cleaning solvent. After cleaning and inspection, soak the chain in the same type and weight oil to be used in the output housing. 6. INSPECTION. A. Roller Chain. Inspect the roller chain for worn pins and rollers, Inspect the surfaces of the inside plates. Wear at this point indicates mis- aligned sprockets and chain life will be impaired. Replace a chain that runs near the top of the sprocket teeth. The chain is wom out if this condition exists. Always adjust the chain if the slack is equal to the pitch which is 3/8-inch. Pitch is the distance from Centerline to pin centerline on the chain link. Keep the chain adjusted!so all slack is removed but no tension is created, B. Sprockets. Inspect the sprockets for wear. If a hook-shaped tooth wear pattern develops, discard the sprockets as this condition will reduce chain life. A new chain should never be installed on an old set of sprockets with a hook-shaped tooth wear pattem. Section III. REMOVAL 7. PRIOR TO REMOVAL. Disconnect the governor drive flexible cable from the governor drive adapter and the idler shaft. Fol- low the procedures described in the main section of this manual for further prior to removal instructions. 8. REMOVAL. Follow the procedures described in the main section of this manual for removal instructions. Section IV. DISASSEMBLY 9. SPROCKET HOUSING GROUP OF | A. Remove the two hex-head ca 74, 6) that secure the cover plate (7) t housing (12). Remove the cover plate plate gasket (8) from the sprocket hou the gasket. B. Remove the master link fr chain (fig. 74, 20), and remove the cha CC. Remove the two hex-head ca 74, 26) that secure the sprocket housi put housing (17). Remove the sprocket attached parts, the sprocket housing s! the sprocket housing gasket (15) fre housing. Discard the gasket. Disas sprocket housing by the following proc (1) Remove the four fiex-he (fig. 74, 1) that secure the governor (2) to the sprocket housing. Remove drive adapter and the adapter gasket sprocket housing. Discard the gasket. (2) Remove the hex-socl plug (fig. 74, 13), or tachometer, from housing. (3) Place the sprocket | attached parts, in position on an arbor the adapter mounting surface is down @ ed. Insert a steel rod that is approxim: Jong through the pipe plug hole in the s ing and center the rod on the idler shaf Exert force on the rod with the arbi Press the idler shaft, with attached p, sprocket housing. (4) Remove the driven s 74, 9), the Woodruff key (10), and tt ball bearing (11) from the sprocket hou: (5) Use a bearing puller the idler shaft ball bearing (fig. 74, 4) shaft. (6) If removal of the idler (fig. 74, 5a) is necessary, split the s move the sleeve from the idler shaft.10. OUTPUT HOUSING. A. Remove the two output housing eyebolts (fig. 71. 16) from the output housing only if replace- ment of parts is necessary. B. Remove the breather cap (fig. 74, 23) from the breather nipple (22). Remove the breather nipple from the output housing only if replacement of parts is necessary C. Remove the oil level gauge (fig. 74, 25) from the oil level gauge tube 21), Remove the oil level gauge tube from the output housing. D. Follow the procedures described in the main section of the manual, and remove the output housing from the converter housing. When accessible, remove the driving sprocket spacer (fig. 74, 21), the criving sprocket (79), and the Woodruif key (13) trom the output shaft. E. Remove the engine oil plate only if re- placement of parts is necessary. Section V. ASSEMBLY NOTE All torques given are with fastener threads dry. 11. OUTPUT HOUSING. A. Follow the procedures described in the main section of the manual, and assemble the output, housing group of parts. Install the Woodruff key (fig. 74, 18) in the output shaft. Align the keyway of the driving sprocket (79) with the key in the shaft, and install the sprocket on the shaft and key with the hub section of the sprocket against the shoulder on the shaft. Instali the driving sprocket spacer (21) on the output shaft and against the driving sprocket. B. Install the oil level gauge tube (fig. 74, 24) in the output housing. Install the oil level gauge (25) in the oil level gauge tube. C. Install a new breather nipple (fig. 74, 22) in the output housing if removal of the nipple had been necessary in disassembly. Install the breather ap (23) on the breather nipple. Hydraulic Torque Converter D. Install the two output housing (fig. 74, 16) in the output housing if remov eyebolts had been necessary in disassembl; 12. SPROCKET HOUSING GROUP OF PAR A. If removal had been necessary, new idler shaft sleeve (fig. 74, 5a) on shaft (5b). B. Press the front ball bearing (fi, onto the idler shaft (5). Press on the bear race with a piece of steel tubing, until th: race butts on the shoulder of the shaft, C. Position the sprocket housing (fi on an arbor press so the 1/4-inch plug hol tacing downward. Lay a 1/4-inch steel pla ich) over the tear ball bearmg bore. Set ball bearing on the plate centered with the bearing bore. Set the driven sprocket (9) + the rear ball bearing centered with the it ‘and with the hub side of the sprocket downy D. Install the Woodruff key (fig. 74 the idler shaft. E. Insert the idler shaft carefully th: front bearing bore of the sprocket housit the Woodruff key with the keyway in th sprocket and press the idler shaft into tt sprocket (fig. 74, 9) and rear ball bearing : it contacts the steel plate. Remove the ste then continue pressing the idler shaft with Parts iato the sprocket housing. F. Install a new adapter gasket (fi ‘and position the adapter (2) and gasket sprocket housing over the idler shaft. Se adapter and gasket to the housing with four cap screws (1) 3/8-16 x 3/4. Tighten the © 38 Ibs.-ft. torque. G. Install the 1/4-inch pipe plug 13). Tighten the pipe plug to 20 Ibs.-ft. torq Section VI. INSTALLATION 13. SPROCKET HOUSING. A. Place a new sprocket housing gas 74, 15) on the output housing (17). Position pack (14) previously removed (or the e thickness in a new pack) on top of the gas Install the sprocket housing (12) in placshim pack and gasket. Secure the sprocket housing to the output housing with two hex-head cap screws (26) 3/8-16 x 1. Tighten the cap screws later (after roller chain installation). B. To install the roller sprocket chain, work through the top cover plate (fig. 74, 7) opening and the front of the converter output housing (17). Attach a suitable length of wire to the chain and fish the chain around the drive sprocket and up to the sides of the driven sprocket. Remove the wire used. Se- cure the chain (20) with the master link. Tum the converter output shaft. so parts align themselves and tighten the sprocket housing mounting cap screw (26) to 38 Ibs.-ft. torque. C. Place a new gasket (fig. 74, 8) on the cover plate (7) mounting surface of tne sprocket housing (12). Install the cover plate (7) and secure Output ' it to the housing with two hex-head ca 3/8-16 x 1, Tighten the cap screws 1 torque. 14. OUTPUT HOUSING. Follow the procedures described in the of the manual to install the output how twcied varts, Attach the govemor drive adapter /fig. 74, 20 Section VIL PARTS LIST 1S. PARTS LIST. Use figure 7% and adjacent parts list spare or replacement parts in accorda: instructions contained sn paragraphs 3 converter manual. ‘GOVERNOR DRIVE ADAPTER sen. L/4.INCHWEX:S0CKET-HEAD antarnan car Tonia caver Rerreoter rig oumurnousine Figure 73 Chain-Driven Governor Group of Parts — Cross-Section View.Hydraulic Torque ConverterOutput ¢ OUTPUT GROUP OF 22S WITH CHAIN-DRIVEN GOVERNOR DRIVE - PARTS LIST lem Description Quanesty SCREW, cap hex-head, 5/1618 x 3/4 ADAPTER, drive, governor GASKET, adapter BALL BEARING, shaft, idler SHAFT, idler, assembly © SLEEVE, shaft, idler b SHAFT, idler SCREW, cap, hexchead, 3/8-16 x 1 PLATE, cover GASKET, plate, cover SPROCKET, driven KEY, Woodruff BALL BEARING, HOUSING, sprocket PLUG, pipe, hex-socket-head, 1/4-inch SHIM, housing, sprocket GASKET, housing, sprocket EYEBOLT, housing, output SCREW, drive PLATE, oil, engine HOUSING, output KEY, Woodruff SPROCKET. driving CHAIN roller SPACE?, sprocket, driving NIPPLE, breather CAP, breather TUBE, cauge, level, oil GAUGE, level, oil SCREW, cap, hex-head, 3/8-16 x 1 ft, idler AAs requiredORIGINAL ISSUE DATE 8/67 SERVICE LETTER No. [REVISED ISSUE DATE 4/79 THREE STAGE CONVE! CENTER FREEWHEEL SERVICE KIT SUMMARY ( Converter Instruction Kit ye) sect Descriptir X203175-B 1.00 $-11569 Std Brg Lock Wash X203175-D 115 8-11560 Sid Bre Lock Wash X 203175-E 1.00 $-11560-1 Integral brg lock nm X203175-F 115 S-11560-1 Integral brg lock nm X 211846 CO 1.00 $-11560-2, New style, spring X211846-A, CO 1.15 S-11560-2 New style, spring Note: New Style Freewheel will not work on FO converters. To rework the old style shafts to incorporate the new style freewheel, the following procedure will be necessary, ~— 4 pest THIS Po 3.41 DRILL 1 HOLE 21/64 x 1.1/4" DEEP 7/8" C'T' BORE .070 + .010" DEEP 9/8-24 UNF ~3B TAP .87 DEEP NOTE: SEE SERVICE LETTERS 71-115 and 74ORIGINAL IssUE DATE 10/68 SERVICE LETTER NO. 73.115, REVISED ISSUE DATE 4/79 ‘THREE STAGE CONVERTERS MODEL CO-1:0 and CO-1.15 CONVERTERS WITH NEW STYLE SPRING LOADED FREEWHEELS “Please refer to Service Letter No. 71-104, showing the procedure required to rework an old style input shaft to the new style input shaft. in order to employ our new style, spring loaded freewheel. You will note we call for a drill and tap hole onthe new style shaft: thus, if you have too large a countersink, after drill and tap, the bearing area will be lost where the spring spacer, 201392-F]. clamps to the shaft. ‘This situation is corrected by first drilling one hole 21/64 x 1.25 inches deep, then machine 7/8 inch counterbore .070 inch plus or minus .010 inch deep before tap: ping 3/8-24 UNF-3B tap .87 inch deep. We have discovered when the bearing area is lost because of too large of countersink, spring spacer will cock, and the freewheel will hang up or drag. The addition of the 7/8 inch counterbore will allow acceptance of one of the hardened washers, A-2888- AY, which is @ component of the cam and roller freewheel kit, X-211846 and X- 221846-A. Current Model CO-1.0 and GO-1.15.Converters employ input shafts 205942-D and 205124-G. In the event freewheel drag is encountered, the above old style shafts must be replaced with the new style shaft with the counterbore. 205942-E replaces 205942-D 205124-H replaces 205124-G . : NOTE: See Service Letter 7411THREE-STAGE TORQUE CONVERTER PINT ING, OFERW CONDITIONS MAXIMUM S10€ LOAD SHAFT States INPUT SWAFT anton 0.000 & Mogel F430 1p GIB 2 750 10.5 C3 See $-10996-4 11s00 Model IF See $2 10376 Ehatn Housing See $-10576 Mode! oF $00.1 Heavy Outy 11,350 See S-490 1.900 AN Mogels $00 1p. C2 $00 1b., C2 See s-475 Velo00 Model F: 16001 2400 10 Models #-16003, F.16008, CF-16005, 1F-1 Mode! IF 9200 1 fleride coupling with capacity to abso Model F-16008 "500 18. naxinun misalignment expected Models F-16010, Feigoll Air Tube Clutche: aiigned to operate et less then O40 Tei ortsetumisalignnent.. Angular reading to 8. Bb. of cluten. (of cluten must be forwa thate’fange Axim sare spceo wODEL Fk OF wODEL CO 8 Cr Serves 10,000—2400 BoM 177 Overcenter Cluteh—2400 PH certes 19° Overcenter Cluten—2100_ RPM Series 12:800—1800 8PM EX-121 Overcenter Clutch—1400 RPM latso see $502} Serves 16200-1800 APH SPl214 Overcenter Cluteh— 1950 RPM (also see $5001 AED INPUT ToRQUE AT GovtsNco RPM MAXIMUM CONVERTER STALL OUTPUT SRE reat yo rarcanere re 1. SATE Ls 28 SHORT THIRD semies roraue seates TURe INE 10,000 Standare 00 T8.tt 19,000 Stangara 3.300 Tete. 5 11500 Standare a0 112800 Stangard 5 113500 Meavy Duty 1.230 115500 Heavy Duty é 131800 Traus erat ean 131800 Indus eetat 10 161000 Indust: 21680 16,000 Industrial " ‘engine RPM exceeds “Rated Input Torque” aj sS the "Maximum values Hist Note 1 If net rmput torque at 901 provides “Converter Stall Output Torque” does not exc Note 2 Mode! CO 19,000 unyt with 3.5" center freewheel is limited to 500 1b. ft. and co 11,5) Center freeunee! Te limited to 700 1b. ft. maximum net Input torque at engine gover Eruet or tractor service. In power Shovel appliestions, these models have the "Stan rating Note 3: Model CD with outboard freewheel has “Standard” series rating. MAXIMUM INPUT TORQUE 10 CLUTCHES ON MODEL CF UNITS 17-inch Bvercanter Clutcn—1990 1b. ft GH-121 chuten—2020 6. te TaHMER Beereentee EMER T AS ABS AE Spobhaehatenteae Ws FE: fLv10 renPcaaruRe> Normal 1n0-220%F5 Haxinue 250¢h, councine eee ssuae a noawAL Seayice owen shove Senviee so-6o psi: asinus a4 8ST 10,000 Serves 20 881 Heavy Duty 11500, 70-60 PSI Max. 95 PSL Wise0 Series = 30 p3 S| ORD? AVAIL. FOR MEAT ExcuANGER FLOW MEAT EXCHANGER CAPACITY eEQUIRED Series 10,000 15 PSI per 100 input horsepower Wormal Industrial Applicat ions-JO% get engiv Sectes 120888 13 REL oe 100 Erovter Tractor Servicecdot mat engine poet Erties 131600 "9 eal per 190 4 Sean fiat FE nc aaa SEriG5 1alb00 7 631 Ber ton taput horsepower contulié hyerasl se’ coins pipe size Series 10,000 ané 11,500, Reavy Duty 1,500, Serves 13,800 and 16,000 NOTE: AT) f9ttings must have an tnstae a ter FLUIOS AMO LUBRICANTS: See Standard Sheet 5-265 and 5-264 Models 1.04 1.15 £0 4 GD (Press. Lub. Design) Lub. Pump to Supply 1-1/2 6.P.M. at Governed En reguiated to 305 PSI ° rte Naldh Garis 180 eiv Z 1\7 Lys Ls 4 Ae 4 a, SVA O ; 7 CNY 4 Y ° ° Pn 2° I 3 4 S 8 8 § $8 8 $ 8 8 s = £ SF SF N S OF HOU CENTER, INCHES 194 U;! UNPUT SPEED IS ENGINE FULL LOAD GOVERNED SPEED. FROM INTERSECTION OF INPUT SPEED ID SPECIFIC TORQUE LINES REAI s O_SPROGKET LOCATION, EKAMPLE SHOWN FOR 10,000 SERIES 320 os 100 SEA WITH SPROCKET LOCATED 3.5 INS. FROM REAR OF HOUSING. USE'Z0 IN. PITCH DIA. 5-7-'52__ RWM TWIN DISC CLUTCH CO.) MINIMUM RECOMMENDED SPROCKET DIAMETERS HYDRAULIC Division Rooke tion HEAVY DUTY, DIREGT CONNEGTED (G3) OUTPUT~~ ae 2 xe ye ONISNOH NIVHO 30M VYLXxX3 Jo VIO HOLId ‘LaN00NdS WAWINIW [~XyW T NIN | HOLId LNIOd 3NOYOL OI14ID3dS LV G33dS GANY3AOD GvoT WIns |H1L331 40 “ON| _NIVHO YO G33dS GVOT 17M4 3NIDN3 WNWIXYW SI G33dS LNdN| [BONVY HLOOL 13490udS| OO}! Sl 3LVOGOWNOS9V TIM ONISNOH ‘VIG HOLId LAXYDONdS WNWIXVW 3HL ,009 SI NOILVOIIddY ANY YOS VIG HOLId L3NDOYdS G3SGNSWWOO3H WNWINIW 3HL —-----— ¥Y3BLY3ANOD OOOO! SaluaS oLb NOISSINSNYYL 0334S ———_ ¥3LY3ANOO 00S'I] S3IuaS OML ONIH3@ O377VLSNI DNINZdO ,8 8 3dAL ONINSO 8 8 3dAL ONINSO ,S'» V 3dAL ONISNOH NIVHO" ALN AAUSH ONISNOH NIVHD ‘hung AAY3H ONISNOH NIVHO "ALG _4HOIT aNOYOL d1519adS » -ANOYOL 91s19ads ANDUOL "9141D3ads o wre 8 o rare ee 2 oN $$ 8 88 & $8 8288 3 8 $ 8 888 £ T 008! f x jv! 8 z kK jos! = 3 {==9 loa: el L 2 t~ 2 8 loooz S a ~ [46 S N }O0%e - pS Po NI 2 SETS Mt a rr ar) sss prs = SBHONI-"VIG HOLId LaNDOYdS 1LNdNO G3GN3NWO93YN WNWINIW TWIN DISG GLUTGH GO., ROGKFORD,ILL. REVISED 5-25-50 5- icsenvice LETTERNo. 7180 ORIGINAL Ist INDEK: THREE STAGE CONVERTERS sflnart FREEWHEELCAM FREEWHEEL CARRIER, ij FREEWHEEL CAGE ASSY. FREEWHEEL SPACER hi mas | swarrins (14) (serine SPRING FREEWHEEL S&S je ROLLERS > Huuty RETURN SPRINGS (2) PIPE FLANGE GASKET (2) RING GAS Procedure for Installing the Cam and Roller Freewheel Kit, X-211846 and X-211846-A, Disasembly of Freewheel. 1. Remove the end plate (clutch housing) from turbine hhousing. ‘The freewheel rollers will fall free. 2 Remove 3/8 x 3 inch x 24 cap serew which holds the freewheel eam carrier to the input shaft. Remove plain washer, spring, and spacer. 5. Remove cam earrice From spline in pump sheet jen springs. ir. K U2 cage ee 1. Reamowe says spacer, Remove from ep 5. Remove the cage assembly. Assembly of Freewheel |. Install eam carrier in the pump wheel spline and against input shaft. 2. Install spacer, spring, and washer in the eam carrie. In- stall cap serew and torque to 38 Ibs. ft ‘3. Install eam and cage assembly on cam carrer. 4. Install 2 cage return springs and 5 bumper spi 5. Install freewheel spacer and snap ring. Gs Uae | rubber band around cage asseme foot string to rubber band. Lead the string throu lade, (ths is for easy removal.) 7. Install 14 rollers in cage assembly. Wher the freewheel rollers have partially enter race, pull on the string until rubber bund ix exy hand and break. The end plate properly locate together with the turbine housing as far as the ¢ gosket NOTE: While installing, rotate the input shaft + permit the freewheel rollers to roll to the low sid when they make contact with the freewheel outer 8 Assemble the end plate to the turbine housit 9. Install the 24 nuts and washers torque to 38